GROUP
Fuel System

Technical Service Bulletin
SUBJECT:

DATE
JANUARY 2025

NUMBER
25-FL-001H
MODEL(S)
SEE BELOW

GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

This TSB supersedes 23-FL-002H-1 to update the entire bulletin to replacement of all GDI
injectors. All sections – including Parts Information, Warranty Information, and Service
Procedure have been updated.
Description: Some vehicles equipped with a 2.5L GDI Theta III engine (non-Turbo) may exhibit one or
more misfire DTCs due to the GDI injectors leaking internally. This may be caused by internal filter
breakage in the injector. Follow the procedure in this TSB to replace all 4 injectors on affected vehicles,
using the kit in the Parts Information section.
Possible misfire DTCs: P0300, P0301, P0302, P0303, P0304

Applicable Vehicles with 2.5L GDI non-Turbo engines:
• 2022MY Santa Cruz (NXT) produced from 05/26/2021 – 06/23/2022 (VINs start with 5NT)
• 2021-2022MY Santa Fe (TMA) produced from 03/01/2021 – 07/15/2022 (VINs start with 5NM)
• 2021-2023MY Sonata (DN8) produced from 02/08/2021 – 01/19/2023 (VINs start with KMH)
• 2021-2022MY Sonata (DN8A) produced from 03/01/2021 – 02/14/2022 (VINs start with 5NP)
• 2022-2023MY Tucson (NX4) produced 01/23/2021 – 11/05/2022 (VINs start with KM8)
• 2022MY Tucson (NX4A) produced 03/01/2021 – 07/11/2022 (VINs start with 5NM)

SST Information:
Tool Name

Tool #

Torque Wrench
Socket

09314-L1100

Figure

Remarks

Use for High Pressure
Fuel Pipe Removal

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

SUBJECT:

Parts Information:
Part Name

Part Number

Figure

Remarks

1

Kit
(contents below)

Use 1 Kit
per vehicle

35399-2S133QQH
2

1. Fuel Injector – GDI

35310-2S000

2. Clip – Fuel Injector

35309-04AA0

3. Pipe – High Pressure

35305-2S000

Qty: 4

3

Qty: 4
Qty: 1
4

4. Gasket - Port

28411-2S010

5. Gasket – Port FKM

28411-2S020

6. Gasket – Throttle Body

28411-2S000

7. Gasket – EGR Pipe

28493-2S000

8. Gasket – Oil Filter Housing

26333-2S000

Qty: 3

5
8

Qty: 1
Qty: 1

7

Qty: 1
Qty: 2

6

Warranty Information:
HMMA models (VINs start with ‘5NP’, ‘5NM’, or ‘5NT’)
Model

Op. Code

Operation

Op.
Time

Causal Part

Nature
Code

Cause
Code

Santa Cruz (NXT)
Santa Fe (TMA)
Sonata (DN8A)
Tucson (NX4A)

20DA14R9

GDI Fuel Injector
Replacement (All
4 Injectors)

1.3
M/H

35310-2S000

W17

ZZ5

HMC models (VINs start with ‘KMH’ or ‘KM8’)
Model
Sonata (DN8)
Tucson (NX4)

Op. Code

Operation

Op.
Time

Causal Part

Nature
Code

Cause
Code

20DA14RA

GDI Fuel Injector
Replacement (All
4 Injectors)

1.3
M/H

35310-2S000

W17

ZZ5

NOTE 1: Submit claim on Campaign Claim Entry Screen as "Campaign" Type.
NOTE 2: If a part is found in need of replacement while performing this TSB 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 a repair validation photo(s). 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.

TSB #: 24-FL-001H

Page 2 of 8
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SUBJECT:

GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

Service Procedure:

STUI
This TSB includes Repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.

Service Procedure Flowchart:

Vehicle In

Check for DTCs

No
(other DTC)

Misfire DTC(s)?
(P0300, P0301,
P0302, P0303,
P0304)

Yes

Injector Replacement
(all 4)

Misfire failure check
(warranty repair)
This TSB does not apply

Vehicle Out

TSB #: 24-FL-001H

Page 3 of 8
SUBJECT:

SUBJECT:

GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

DTC Inspection
Perform a Fault Code Search for one or more of the following misfire DTCs:
•

P0300, P0301, P0302, P0303, P0304

If one or more of these are found, and vehicle falls within the Applicable Vehicle range, proceed to
Injector Replacement.
If none of these DTCs are found, and/or vehicle is NOT within the Applicable Vehicle range, then this
TSB does NOT apply. Continue with normal diagnosis and repair.
Injector Replacement
1.

Release the Residual Pressure in the Fuel
Line.
Refer to Shop Manual:
• Engine Control / Fuel System > Fuel
Delivery System > Release Residual
Pressure in Fuel Line

2.

3.

Record customer’s radio presets, if applicable,
then turn ignition OFF and disconnect the
negative (–) battery cable.

A

Remove the engine cover (A).
Refer to Shop Manual:
• Engine Mechanical System > Engine
And Transaxle Assembly > Engine
Cover > Repair procedures

4.

Remove the ignition coil connectors (B), then
remove the ignition coil foam (C).
B

C

TSB #: 24-FL-001H

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GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

SUBJECT:

5.

Remove the high pressure pump foam (D).

D

6.

Remove the air cleaner assembly.
Refer to Shop Manual:
• Engine Mechanical System > Intake
And Exhaust System > Air Cleaner >
Repair procedures

7.

Remove the high pressure fuel pipe bracket
bolts (E), then remove the flange nut (F).

F

Tightening Torque:
Bracket bolts:
lb-ft

7.9

lb-in

95
E

N.m

11

Flange nut:
lb-ft

22

N.m

29

TSB #: 24-FL-001H

Page 5 of 8
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GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

SUBJECT:

8.

Remove the intake manifold (G).
Refer to Shop Manual:
• Engine Mechanical System > Intake
And Exhaust System > Intake
Manifold > Repair procedures

9.

G

Remove the injector foam (H).

H

10.

Remove the high pressure fuel pipe flange
nut (I).

11.

After removing the 4 bolts (J), remove the
delivery pipe and injector assembly.
I

Tightening Torque:
Flange nut (I):
lb-ft

22

N.m

29

J

Bolts (J):
lb-ft

16

N.m

21

TSB #: 24-FL-001H

Page 6 of 8
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GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

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12.

Disconnect the injector and rail sensor
connectors (K).

13.

Remove the injectors from the fuel rail (L) after
releasing the clips (M) on both sides.

14.

K

L

Install the new injector parts in the reverse
order of removal.

i

Information

Before installing new injectors be sure to
clean each cylinder head hole. Use a
brush to remove carbon deposits and
foreign materials.

i

M
M

Information

GDI Fuel Injector components:
• Combustion seal (N)
• Rubber washer (O)
• Injector clip (P)
• Support disk (Q)
• O-ring (R)

N

O

R

NOTICE
•
•
•
•
•
•

Be careful NOT to deform the new
high pressure fuel pipe.
When inserting the injector, be careful
NOT to damage the injector tip.
Do NOT apply oil, grease, or lubricant
to the combustion seal.
Do NOT tilt the torque wrench when
tightening nuts.
Carefully observe all torque
specifications.
Use SST 09314-L1100 for installing
the high pressure fuel pipe flange nut.

TSB #: 24-FL-001H

P

Q

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SUBJECT:

GDI INJECTOR REPLACEMENT DUE TO MISFIRE DTC(S)

15.

STUI
Using STUI, take a photo of the new
injectors next to the old injectors with
the fuel rail removed with the last 6
digits of the VIN and the date of repair
on a piece of paper.
Upload the photo to STUI.

16.

Reinstall all remaining parts in reverse order of
removal.

17.

Reset customer’s radio presets, if applicable,
and reconnect the negative (–) battery cable.

18.

Start the engine and confirm proper operation
of the vehicle.

TSB #: 24-FL-001H

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