NHTSA ID Number: 11008137
Manufacturer Communication Number: 24-01-080H
TSB/Document Date: 2024-09-30
Summary
The exhaust gas recirculation (EGR) valve assembly in certain vehicles (listed below) may contain a sensor that was contaminated with solder flux during manufacturing, which could potentially result in an electrical short. An electrical short within the EGR valve could lead to a Malfunction Indicator lamp (MIL) illumination (P0405, P0642, P0652, P0404/P049D/P240F). Follow the information in this bulletin to replace the EGR valve assembly and gasket.
GROUP
NUMBER
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
24-01-080H
MODEL(S)
SEPTEMBER 2024
SEE BELOW
EGR VALVE ASSEMBLY AND GASKET REPLACEMENT
(SERVICE CAMPAIGN 9B3)
IMPORTANT
Dealers must perform this service campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
Access the “Vehicle Information” screen via WebDCS to identify open campaigns.
Description: The exhaust gas recirculation (EGR) valve assembly in certain vehicles (listed below) may
contain a sensor that was contaminated with solder flux during manufacturing, which could potentially
result in an electrical short. An electrical short within the EGR valve could lead to a Malfunction Indicator
lamp (MIL) illumination (P0405, P0642, P0652, P0404/P049D/P240F). Follow the information in this
bulletin to replace the EGR valve assembly and gasket.
Applicable Vehicles (Certain):
• 2024MY Tucson (NX4) equipped with Theta 2.5 GDI and produced 01/17/2024–02/22/2024
• 2024MY Sonata (DN8) equipped with Theta 2.5 GDI and produced 02/06/2024–02/16/2024
• 2024MY Sonata Hybrid
(DN8 HEV) equipped with Nu 2.0 GDI and produced
02/06/2024–02/24/2024
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
Parts Information:
Vehicle
Part Name
9B3
Campaign
Sticker
NP001-SC9B3
NP001-SC9B3
Vehicle
Emission
Recall - Proof
of
Correction
Card
Remarks
Qty: 1
Apply to all vehicles
regardless of state.
Qty: 1
Order only for states: CA,
CO, CT, DE, ME, MD, MA,
NJ, NY, OR, PA, RI, VT,
WA
NP050-09006
EGR Valve Assembly
28400-2J310QQH
Qty: 1
Gasket - EGR Pipe
28492-2J000QQH
Qty: 1
EGR Valve Assembly
28400-2S000QQH
Qty: 1
28493-2S040QQH
Qty: 1 (in)
28493-2S030QQH
Qty: 1 (out)
Crankshaft Position Sensor
(CKPS)
39180-2S000QQH
Qty: 1
00232-19098WAR (1 Quart)
Qty 5: Sonata
Qty 6: Tucson
Allowance for 5 quarts
have been included; do not
use 100% full strength.
Prepare coolant mixed with
distilled/filtered water to
refill the cooling system.
45-60% coolant, diluted
with water)
Sonata Hybrid
(DN8 HEV)
Gasket - EGR Pipe
Sonata
(DN8)
&
Tucson
(NX4)
Part Number
TSB #: 24-01-080H
Page 2 of 16
SUBJECT:
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
Parts Information (continued):
Vehicle
Part Name
Part Number
Remarks
Gasket - Exhaust Pipe
28751-D4350
Gasket - Exhaust Pipe
28751-3S100
Gasket - EGR Pipe
28493-2S010
Gasket - EGR Pipe
28493-2S020
Sonata
(DN8)
28751-2S001QQH
Gasket - Catalyst Case
28535-2SAD0
Gasket - Thermostat Housing
25623-2S600
O-Ring
25462-2S000
O-Ring
25462-2S500
Gasket - EGR Pipe
28493-2S000
Gasket - EGR Cooler
28493-2S050
EGR Service Kit
(each kit has 1 part each,
as specified within
the Remarks)
Gasket - Exhaust Pipe
28751-3S100
Gasket - Exhaust Pipe
28751-2S000
Gasket - EGR Pipe
28493-2S010
Gasket - EGR Pipe
28493-2S020
Tucson
(NX4)
28751-2S002QQH
Gasket - Catalyst Case
28535-2SAD0
Gasket - Thermostat Housing
25623 - 2S600
O-Ring
25462 - 2S000
O-Ring
25462 - 2S500
Gasket - EGR Pipe
28493 - 2S000
Gasket - EGR Cooler
28493 - 2S050
NOTE 1: Order 1 kit for the specified Tucson/Sonata along with the applicable parts listed on page 1.
TSB #: 24-01-080H
Page 3 of 16
SUBJECT:
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
Warranty Information:
Model
Op. Code
Sonata Hybrid
(DN8 HEV)
40D076R0
Sonata (DN8)
40D076R7
Tucson (NX4)
40D076R8
Operation
EGR Valve
Assembly and
Gasket
Replacement
Op. Time
Causal Part
0.5 M/H
28400-2J310
2.4 M/H
2.5 M/H
Nature
Code
Cause
Code
W11
ZZ7
28400-2S000
NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: If a part is found in need of replacement while performing this campaign and the affected
part is still under warranty, submit a separate claim using the same repair order. If the affected part is
out of warranty, submit a Prior Approval request for goodwill consideration prior to performing the
work.
NOTE 3: This TSB includes Repair validation photos. Op times include VIN, Mileage, and Repair
validation photo(s) as outlined in the Digital Documentation Policy.
NOTE 4: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
Service Procedure: Sonata Hybrid starts on page 3, Sonata & Tucson start on page 8.
STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.
EGR Valve Assembly and Gasket Replacement – Sonata Hybrid (DN8 HEV)
1.
Refer to the shop manual to disconnect the
high-voltage circuit:
• General Information > High Voltage
Shutoff Procedure
Record customer preset radio stations if
applicable.
Disconnect the 12V positive connector (A)
from the auxiliary battery.
TSB #: 24-01-080H
A
Page 4 of 16
SUBJECT:
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
2.
Disconnect the service interlock connector (B).
! CAUTION
Wait for at least 3 minutes to ensure the
capacitor in the high voltage system is
fully discharged.
3.
Loosen the mounting clamps (C) and remove
the air intake hose (D).
B
C
Tightening Torque:
4.
lb-ft
9.8
lb-in
117
N.m
3.7
D
C
Disconnect the EGR control valve
connector (E).
E
TSB #: 24-01-080H
Page 5 of 16
SUBJECT:
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
5.
Remove the mounting nuts (F) of the EGR
valve cooler pipe.
Tightening Torque:
lb-ft
22
N.m
16
F
F
6.
Remove the mounting bolts (G), and remove
the EGR valve (H).
Tightening Torque:
lb-ft
22
N.m
16
H
G
TSB #: 24-01-080H
Page 6 of 16
SUBJECT:
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
7.
i
Information
Gasket
Mount the EGR pipe gasket before
installing the EGR valve assembly.
Tighten the EGR control valve to the
specified torque.
Avoid dropping the EGR control valve to
prevent internal damage. Do NOT use if
damaged.
Prevent foreign substances from entering
the EGR control valve.
Orient the EGR pipe gasket as shown in
photo.
8.
9.
EGR Valve Assembly
Reinstall components in the reverse order of
the removal process.
STUI
Using STUI, take a photo of the newly
installed EGR Valve capturing the
production stamp with the last 6 digits
of the VIN and the date of repair on a
piece of paper.
Upload the photo to STUI.
TSB #: 24-01-080H
Page 7 of 16
SUBJECT:
SUBJECT: EGR VALVE ASSEMBLY AND GASKET REPLACEMENT (SERVICE CAMPAIGN 9B3)
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TSB/Document ID: 24-01-080H
Replacement Service Bulletin Number:
MFR Communication Date: 2024-09-25
MFR Internal Campaign ID/Software Version: SERVICE CAMPAIGN 9B3
Communication Type: Service Campaign
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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