GROUP

NUMBER

ENGINE
ELECTRICAL
DATE

Technical Service Bulletin

MODEL(S)
SONATA
(DN8/DN8A)

APRIL 2025
SUBJECT:

25-EE-002H

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Description: Certain Sonata (DN8) and Sonata (DN8A) vehicles may experience issues with the air
conditioning due to damaged wiring in the engine room junction box. This bulletin provides instructions
to replace the multi-fuse, reroute the damaged wiring using the blower wiring kit, and replace the fuse
label.
Applicable Vehicles:
• 2021-2023MY Sonata (DN8) produced from 02/08/2021 - 09/15/2022 (VIN starts with 'KMH')
• 2020-2022MY Sonata (DN8A) produced from 10/22/2019 - 02/17/2022 (VIN starts with '5NP')
Parts Information:
Model

Part Name

Part Number

Multi-fuse

18980-09910FFF

Figure

Remarks

Qty: 1

A

B

Sonata
(DN8/
DN8A)
Blower
Wiring Kit

91200-L1000FFF
C
D
E

A. Band cable
(qty: 2)
B. Wiring terminal
C. Retainer
(relay unit)
RBL04-02465
D. Fuse label 50A
E. Blank fuse
label

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

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

SUBJECT:

Required Equipment/Supplies:
Name

Equipment/Supply #

Insulating Tape

N/A

Figure

Remarks

Standard shop supply

Warranty Information:
Model

Op. Code

Sonata
(DN8/DN8A)

91200F06

Operation

Op.
Time

Causal Part

Multi-Fuse Replacement &
0.7 M/H 91215-L1020
Blower Wiring Repair

Nature
Code

Cause
Code

I41

ZZ3

NOTE 1: Normal warranty applies.
NOTE 2: Submit claim on Claim Entry Screen as “Warranty” type.
NOTE 3: Take a picture of the warrantable defect. 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.
NOTE 5: 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.

TSB #: 25-EE-002H

Page 2 of 10
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SUBJECT:

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Service Procedure:

DIGITAL DOCUMENTATION
This TSB includes Repair justification photos. Refer to the latest Warranty Digital
Documentation Policy for requirements.
1.

2.

Verify if the blower fuse and terminals are
discolored.
• If either the blower fuse and/or
terminals are discolored, then proceed
with the service procedure.
• If the blower fuse and terminals are
NOT discolored then this TSB does
NOT apply. Continue with a normal
diagnosis.

DIGITAL
DOCUMENTATION

Using STUI, take a photo of the
discolored blower fuse and/or
terminals with the last 6 digits of the
VIN and the date of repair on a piece
of paper.
Upload the photo to STUI.

TSB #: 25-EE-002H

Page 3 of 10
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MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

SUBJECT:

3.

To remove the air duct and air cleaner
assembly, refer to the shop manual:
• Engine Mechanical System >Intake
and Exhaust System > Air Cleaner >
Repair procedures

A

To remove the battery and battery tray, refer to
the shop manual:
• Engine Electrical System > Charging
System > Battery > Repair
procedures
Remove the following parts:
• engine room junction box connector
• terminals
• 2 multi-fuse
• band cable (A)

i

Information

Modified fuses (18980-09910) are
replaced with new ones, while reused
fuses (18980-09920) remain in place.

TSB #: 25-EE-002H

Page 4 of 10
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SUBJECT:

4.

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Remove the mounting bolt (B) and nut (C) of
the junction box.

C

B

DN8A
DN8

5.

Use the remover tool to remove the junction
box (D).

D

TSB #: 25-EE-002H

Page 5 of 10
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SUBJECT:

6.

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Lift up and remove the junction box (E).

E

7.

Cut two band cables (F) and remove the
insulating tape (G).
Remove the back cover of the junction box.
F
F

G

TSB #: 25-EE-002H

Page 6 of 10
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SUBJECT:

8.

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Remove terminal 13 (H) from the blower motor
relay (female terminal, 4 pins).

H

Remove

9.

Cut the wiring from the removed terminal and
wrap the remaining harness securely using
insulating tape (I).

I

TSB #: 25-EE-002H

Page 7 of 10
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SUBJECT:

10.

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Install the supplied wiring terminal from the kit
into the connector (J).

J

Relay terminal

Relay terminal

TSB #: 25-EE-002H

Page 8 of 10
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11.

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

Install the multi-fuse air terminal with the other
side of the supplied wire terminal, ensuring
proper installation between the white and
orange wires (K).
K

K

Multi-fuse air terminal

TSB #: 25-EE-002H

Page 9 of 10
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SUBJECT:

MULTI-FUSE REPLACEMENT & BLOWER WIRING REPAIR

12.

Place the Blank label over the existing 40A
label in the red dotted area below in step 13.
Place the 50A label in the blue dotted area
(currently no label) below in step 13.

13.

Reinstall parts in the reverse order of the
removal.Current routing before cutting and rerouting after cutting (L).

L

Before
After
Cutting

14.

Confirm air conditioning is working.

15.

The service procedure is now complete.

TSB #: 25-EE-002H

Page 10 of 10
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