Qty: 1

54559-1F000

54559-1F000

Qty :2

14331-12160

14331-12160

Qty :2

Not Applicable
Not Applicable

49129-C5200
49129-4H700

Qty: 3
Qty: 4

TSB #: 25-EM-008H

Page 4 of 29

SUBJECT:

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Warranty Information (Inspection Op. Codes):
Model

Op. Code

Operation

Op. Time

40D119I0

Seized/External Damage (YES) + Oil Cap Condition (PASS) + Submit PA
Includes: Engine Rotation Check

0.6 M/H

40D119I1

Seized/External Damage (YES) + Oil Cap Condition
(PASS/NO PASS) + Rear Bank Rocker Cover Removal + Submit PA
Includes: Engine Rotation Check

1.6 M/H

40D119I2

Seized/External Damage (NO) + BCT Front Bank (NO PASS) + Oil Cap
Condition (PASS) + Submit PA

0.7 M/H

40D119I3

Seized/External Damage (NO) + BCT Front Bank (NO PASS) + Oil Cap
Condition (PASS/NO PASS) + Rear Bank Rocker Cover Removal +
Submit PA

1.7 M/H

Seized/External Damage (NO) + BCT Front & Rear Bank (NO PASS /
NO BCT) + Oil Cap Condition (PASS) + Submit PA
Includes: Compression Test for No BCT

1.7 M/H

40D119I5

Seized/External damage (NO) + BCT Front & Rear Bank (NO PASS / NO
BCT) + Oil Cap Condition (PASS/NO PASS) + Rear Bank Rocker Cover
Removal + Submit PA
Includes: Compression Test for No BCT

2.0 M/H

40D119I6

Seized/External Damage (NO) + BCT Front & Rear Bank (PASS) +
Reassemble Engine + Follow Normal Diagnostics (TT’) + Submit PA +
Engine Replacement Recommended

1.9 M/H

40D119I7

Seized/External Damage (NO) + BCT Front & Rear Bank (PASS) +
Reassemble Engine + Follow Normal Diagnostics (TT’) + Engine
Replacement NOT Recommended

1.7 M/H

Santa Fe
/ Santa
Fe XL
40D119I4
(NC)

TSB #: 25-EM-008H

Page 5 of 29

SUBJECT:

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Warranty Information (Engine Replacement/Reinstallation Op. Codes):
Model

Op. Code

Operation

Op. Time

40D245R1

Engine Sub-Assembly
Replacement (2WD)
(P/N 117R1-3CS00QQH)
(Wheel Alignment Adjustment
Included)

8.8 M/H

40D245R2

Engine Sub-Assembly
Replacement (4WD)
(P/N 137Q1-3CS00QQH)
(Wheel Alignment Adjustment
Included)

9.2 M/H

Santa Fe /
Santa Fe XL 40D245R3
(NC)

Engine Sub-Assembly
Replacement (4WD)
(P/N 118R1-3CS00QQH)
(Wheel Alignment Adjustment
Included)

9.2 M/H

40D245R0

Engine Sub-Assembly
Replacement (2WD)
(P/N 135Q1-3CS00QQH)
(Wheel Alignment Adjustment
Included)

8.8 M/H

Engine Sub-Assembly
Reinstallation
40D245R4
NOT Replaced
(PA Declined or Engine
Replacement NOT recommended)

Causal Part

173R1-3CA00

Nature Code Cause Code

Q55

ZZ1

0.6 M/H

NOTE 1: Submit claim under ‘Campaign’ Entry screen.
NOTE 2: All ‘TT’ time must be submitted under 1 separate claim using the same repair order number:
• If a part is in need of replacement and the malfunction is directly caused by Warranty Extension TXX8 related engine
failure, or if additional labor is required while performing Warranty Extension TXX8:
o Submit with 173R1NTT using the engine causal part number associated with the TXX8 op code AND
o Ensure part replacement and punch times are accurate and that they match the labor performed along with the
service manager's signature approving the TT time.
o Refer to Documents Library posting for details regarding ATT/NTT Best Practice Guide. Location: Hyundai
Tech Info > Service > WebDCS > Warranty > Warranty Support Portal > Search ‘ATT’ > Select ‘ATT/NTT
Best Practice Guide and Supplemental Worksheet
• NOTE: If the part replacement does not require additional labor, follow the above steps and use the system minimum of
.00 labor time with a quantity of 1.
• For Op Codes 40D119I6 and 40D119I7, submit for ‘TT’ time to identify root cause of engine noise. Op code 40D119I7 is
for vehicles that have confirmed external engine noise and do not require an engine replacement.
• For OP Code 40D119I6, submit for ‘TT’ time if the PA Department requests rocker cover removal. For certain op codes,
labor time for removal of the Rear Bank Rocker Cover (RH) is included if mentioned in applicable operation’s description
NOTE 3: If a part is found in need of replacement while performing this warranty extension and the affected part (malfunction not
directly caused by TXX8) is still under warranty, submit a separate claim using the same repair order. If the affected part(s) are
out of warranty, submit a Prior Approval request for goodwill consideration prior to performing the work.
NOTE 4: If the Engine Sub-Assembly is declined or replacement is not recommended, replace all non-reusable parts and use
OP code 40D245R4.
NOTE 5: Two op codes may be submitted, one for inspection and one for engine replacement.
NOTE 6: If engine replacement is required, dealers will be compensated for 7 quarts of engine oil under part number 00232ENGOILWAR and 2 gallons of green coolant under part number 00232-19010.
NOTE 7: Refer to the 1st Warranty table for the causal part, nature code, and cause code.

TSB #: 25-EM-008H

Page 6 of 29

SUBJECT:

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Service Procedure:

DIGITAL DOCUMENTATION
This TSB includes repair validation photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.

NOTICE
Applying the recommended torque to all fasteners is essential to reduce potential issues from
occurring after the service procedure.

Table of Contents
•

Engine Oil Maintenance Information.........................................................................................7

•

Initial Inspection ........................................................................................................................9

•

Engine Rotation Check ........................................................................................................... 10

•

Bearing Clearance Test (BCT) ............................................................................................... 12

•

Engine Replacement .............................................................................................................. 14

•

Appendix: Op. Code Reference Guide ................................................................................... 19

Engine Oil Maintenance Information
Poor oil maintenance can reduce engine
lubrication and cooling efficiency. This may cause
abnormal internal engine wear, carbon, buildup,
sludge, and other issues. These conditions may
require inspection before engine warranty
approval.

NOTICE
•
•
•

Engine oil lubricates, cools, and
operates key engine components.
Regular oil changes and oil level
checks are required for all engines.
Check and top off engine oil as needed
between oil changes.

Piston Ring Deposits

Oil Sludge

Excessive Wear
TSB #: 25-EM-008H

Page 7 of 29

SUBJECT:

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Service Procedure Flowchart:

TSB #: 25-EM-008H

Page 8 of 29

SUBJECT:

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Initial Inspection
1.

Verify if the vehicle is within the TXX8 warranty extension coverage:

i

Information

The warranty coverage for the engine repair or replacement related to engine noise or
damage has been extended to 15 years or 150,000 miles from the date of original retail
delivery or date of first use, whichever comes first. Warranty coverage is valid for original
and subsequent owners.
•
•

2.

If the vehicle is within warranty coverage, proceed with step 2.
If the vehicle is out of warranty coverage, then this TSB does NOT apply. Follow normal
diagnostic procedures.
o The service procedure is now complete.

Remove the engine oil cap.

i

Information

The oil cap condition will be used to
determine if the rear bank rocker cover
removal is needed.
3.

DIGITAL
DOCUMENTATION

PASS

Using STUI, take a photo of the engine
oil cap with the last 6 digits of the VIN
and the date of repair on a piece of
paper.
Upload the photo to STUI.

NO PASS

TSB #: 25-EM-008H

Page 9 of 29

SUBJECT:

4.

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Inspect for engine seize or external lower end damage to the cylinder block:
• If engine is NOT seized and external damage is NOT found, then proceed to the
Bearing Clearance Test (BCT) procedure.
• If engine is seized or external damage is found:
A. Capture at least 1 photo of the damage for PA.
B. Remove the rear bank rocker cover depending on the oil cap condition chart on
step 3 of page 9.
C. Submit a PA.

NOTICE
PA is required for engine replacement. Submit a PA and refer to the Dealer Best Practices
guide for the latest requirements for engine approval.

•

A picture of the lower end damage is required if present.

Additional documentation may be required:
•

•

Refer to the Prior Approval Submission Documentation’s last page for PA required
items located on Hyundai Tech Info (HTI).
HTI > Service > Dealer Resources > Documents Library > Warranty >
‘Engine PA Required Documentation’ and/or ‘PA Dealer Best Practices’
Use the STUI feature on the GDS to take and submit pictures.

Engine Rotation Check
1.

Rotate the crankshaft with the crankshaft
rotator tool.
• If the crankshaft does NOT turn with
moderate force, measure the required
torque with a torque wrench.
• If the SST or shop tools do NOT fit the
vehicle, then remove the front
passenger wheel, wheel liner, or
underbody tray as needed.

NOTICE
If engine accessory components are
seized, then remove the accessory belt
before performing the crankshaft rotation
check.

TSB #: 25-EM-008H

Page 10 of 29

SUBJECT:

2.

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Evaluate the crankshaft rotation:
• If the crankshaft rotates up to 2 full
turns (720 degrees) then proceed to
the Bearing Clearance Test (BCT)
procedure.
• If torque required exceeds 94 lb-ft,
then documentation via STUI video is
required. Proceed to step 3.

i

Information

All vehicles in this TSB must complete a
Bearing Clearance Test (BCT) unless the
engine is seized or external damage is
visible.

NOTICE
PA is required for engine replacement. Submit PA and refer to the Dealer Best Practices guide for
the latest requirements for engine approval.
If the engine does NOT rotate properly, the following STUI video is required:
•
•
•

VIN plate (on windshield or doorjamb)
Attempt to rotate the crankshaft with a torque wrench set to 94 lb-ft
Save and submit the torque value.

Additional documentation may be required:
•

•

Refer to the Prior Approval Submission Documentation’s last page for PA required items
located on Hyundai Tech Info (HTI).
HTI > Service > Dealer Resources > Documents Library > Warranty >
‘Engine PA Required Documentation’ and/or ‘PA Dealer Best Practices’
Use the STUI feature on the GDS tablet to take and submit pictures.

TSB #: 25-EM-008H

Page 11 of 29

SUBJECT:

ENGINE NOISE INSPECTION & REPLACEMENT (WARRANTY EXTENSION TXX8)

Bearing Clearance Test (BCT)

i

Information

Refer to 25-EM-006H (or latest version), Bearing Clearance Test Service Procedure
Perform BCT:
A. If the BCT result is PASS
o Save a screenshot of the result.