Hyundai - ELANTRA HD - Service Guide - 2020 - 2020

GROUP RECALL DATE JUNE, 2020 Technical Service Bulletin SUBJECT: NUMBER 20-01-017H-1 MODEL(S) ELANTRA (HD) ELANTRA TOURING (FD) SANTA FE (CM) ENTOURAGE (EP) 2007-2010 ELANTRA (HD), 2009-2011 ELANTRA TOURING (FD), 2007 SANTA FE (CM) AND 2007-2008 ENTOURAGE (EP) PCB RELAY KIT INSTALLATION (RECALL CAMPAIGN 188) This TSB supersedes TSB# 20-01-017H, adding procedures and parts for Santa Fe (CM) and Entourage (EP) vehicles.  IMPORTANT *** Retail Vehicles *** Dealers must perform this Recall Campaign whenever an affected vehicle is in the shop for any maintenance or repair. When a vehicle arrives at the service department, access Hyundai Motor America’s “Vehicle Information (VIS)” screen via WEBDCS to identify open Campaigns. Description: Moisture may enter the ABS electrical system of certain Elantra (HD), Elantra Touring (FD), Santa Fe (CM) and Entourage (EP) vehicles. Over time, the moisture can cause a short circuit. If a short circuit occurs inside the ABS module, there could be an increased risk of an engine compartment fire. This bulletin describes the procedure to install a relay into the ABS module electrical circuit. Applicable Vehicles: Certain 2007-2010MY Elantra (HD) and 2009-2011MY, Elantra Touring (FD), 2007-2008MY Entourage (EP) and 2007MY Santa Fe (CM) vehicles produced by Hyundai Motor Company Korea (VIN beginning with a “K”) Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service Advisors, Technicians, Body Shop Manager, Fleet Repair RECALL 188 – PCB RELAY BLOCK INSTALLATION SUBJECT: Parts Information: MODEL PART NAME FIGURE / PART NUMBER PCB Relay Kit 1 1 3 2 Elantra (HD) Elantra Touring (FD) QTY. (1) Junction Box Upper Cover (2) Extension Wire (3) Label (4) Rubber Packing (5) Fuse Bolts (6) PCB Relay Block 6 4 5 91940-2H001-QQH 2 3 4 Santa Fe (CM) PCB Relay Kit 5 (1) Junction Box Upper Cover (2) Extension Wire (3) Fuse Bolts (4) Rubber Packing (5) MIDI Fuse (6) PCB 1 1 6 91940-2B005-QQH (1) Junction Box Upper Cover (2) PCB (3) Extension Wire 1 PCB Entourage Relay (EP) Kit 1 2 3 91940-4D001-QQH TSB #:20-01-017H-1 Page 2 of 14 SUBJECT: SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION Model Op. Code Elantra (HD) Elantra Touring (FD) 01D010R0 Santa Fe (CM) 01D010R1 Entourage (EP) 01D010R2 Operation Op. Time PCB Relay Kit Installation 0.3 M/H Causal Part No. 91940-2H001 -QQH 91940-2B005 -QQH 91940-4D001 -QQH Nature Code Cause Code I11 ZZ3 NOTE 1: Submit Claim on Campaign Claim Entry Screen NOTE 2: If a part is found in need of replacement while performing Recall 188 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. NOTICE The service procedure for each model begins on the pages noted below: Elantra (HD)/Elantra Touring (FD): Page 3 Santa Fe (CM): Page 8 Entourage (EP): Page 12 Service Procedure: Elantra (HD)/Elantra Touring (FD) NOTICE If the “ABS”, “ESC” or “Brake” indicator lamps are illuminated, refer to the appropriate section of the repair manual prior to installing the PCB Relay Kit. 1. If applicable, record the customer’s radio preset stations. 2. Turn the ignition switch OFF, disconnect the battery negative (-) terminal and remove the junction box cover (A). TSB #:20-01-017H-1 A Page 3 of 14 SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION SUBJECT: 3. Remove and discard the blue 20A (B), green 40A (B1) and two red 10A (B2 and B3) fuses. B3 B 4. B2 B1 Remove the fuse mounting bolts (C). NOTICE C Do not remove the 125 amp fuse. 5. Install the rubber packing (D) over the mounting bosses. TSB #:20-01-017H-1 C D D Page 4 of 14 SUBJECT: SUBJECT: 6. RECALL 188 – PCB RELAY BLOCK INSTALLATION Remove the gray terminal covers (E) and install the PCB relay block. E E 7. Install and tighten the fuse bolts (F). Tightening Torque: 3.9~4.9 Nm (0.4~0.5 kgf.m, 2.9~3.6 lb-ft) F TSB #:20-01-017H-1 F Page 5 of 14 SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION SUBJECT: 8. Route the extension wire through the channel (G) of the new junction box upper cover. G 9. Attach the label (H) to the inside of the new junction box upper cover. H 10. Connect the extension wire connector (J) to the PCB relay block (I). I NOTICE When connecting the extension wire to the PCB relay block, confirm a clicking sound is heard. TSB #:20-01-017H-1 J Page 6 of 14 SUBJECT: SUBJECT: 11. RECALL 188 – PCB RELAY BLOCK INSTALLATION Reconnect the negative (-) battery terminal. Connect the extension wiring (K) to the negative (-) battery cable terminal and tighten the nut (L). Tightening Torque: 19.6~29.4 Nm (2.0~3.0 kgf.m, 14.5~21.7 lb-ft) 12. 13. K L Confirm the extension wire stays routed in the junction box upper cover channel (M) and install the new junction box upper cover (N). Start the engine. Confirm the “ABS”, “ESC” and “Brake” indicator lamps are not illuminated, clear any incidental DTCs and reprogram the customer’s radio preset stations. TSB #:20-01-017H-1 N M Page 7 of 14 SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION SUBJECT: Service Procedure: Santa Fe (CM) NOTICE If the “ABS”, “ESC” or “Brake” indicator lamps are illuminated, refer to the appropriate section of the repair manual prior to installing the PCB Relay Kit. 1. If applicable, record the customer’s radio preset stations. 2. Turn the ignition switch OFF, disconnect the battery negative (-) terminal and remove the junction box upper cover (A). 3. A Remove and discard the red 10A (B), green 40A (B1) and blue 20A (B2) fuses. B B1 B2 4. Remove the two bolts from the MIDI fuse (C). NOTICE C Not all applications will have a MIDI fuse in this location. C TSB #:20-01-017H-1 Page 8 of 14 SUBJECT: SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION If a MIDI fuse was not originally installed in this location (D), install the new MIDI fuse included in the PCB Relay Kit. D 5. Install the rubber packing (E) on the mounting bosses. E E 6. Remove the new PCB assembly terminal protection cover (F) and install the PCB assembly. F TSB #:20-01-017H-1 Page 9 of 14 SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION SUBJECT: NOTICE PCB terminal (G) is seated in the junction box where the 10A fuse was removed (H). G H 7. Install and tighten the new PCB fuse bolts (I). Tightening Torque: 3.9 ~ 4.9 Nm (0.4 ~ 0.5 kgf. m, 2.9 ~ 3.6 lb-ft) 8. I I Remove the body ground bolt and reinstall it with the extension wire terminal (J) attached. Tightening Torque: 10.7 ~ 13.7 Nm (1.1 ~ 1.4 kgf.m, 7.9 ~ 10.1 lb-ft) J TSB #:20-01-017H-1 Page 10 of 14 SUBJECT: SUBJECT: 9. RECALL 188 – PCB RELAY BLOCK INSTALLATION Connect the extension wire connector (K) to the PCB assembly (L), and reconnect the negative (-) battery terminal. L K NOTICE When connecting the extension wire to the PCB relay block, confirm a clicking sound is heard. 10. Install the new junction box upper cover (M). 11. Start the engine. Confirm the “ABS”, “ESC” and “Brake” indicator lamps are not illuminated, clear any incidental DTCs and reprogram the customer’s radio preset stations. TSB #:20-01-017H-1 M Page 11 of 14 SUBJECT: SUBJECT: RECALL 188 – PCB RELAY BLOCK INSTALLATION Service Procedure: Entourage (EP) NOTICE If the “ABS”, “ESC” or “Brake” indicator lamps are illuminated, refer to the appropriate section of the repair manual prior to installing the PCB Relay Kit. 1. If applicable, record the customer’s radio preset stations. 2. Turn the ignition switch OFF, disconnect the battery negative (-) terminal and remove the junction box upper cover (A). 3. A Remove and discard the red 10A (B), blue 20A (B1) and green 40A (B2) fuses. B B1 4. Remove the new PCB assembly terminal protection cover (C). TSB #:20-01-017H-1 B2 C Page 12 of 14 SUBJECT: SUBJECT: 5. RECALL 188 – PCB RELAY BLOCK INSTALLATION Connect the extension wire connector (D) to the PCB assembly (E) and install the PCB relay block. NOTICE When connecting the extension wire to the PCB relay block, confirm a clicking sound is heard. E D 6. Route the extension wire (F) around the rear of the junction box to the battery in the gap (G) between the air cleaner housing and the junction box. G F The extension wire should be routed beside the BCM-FE wire harness (H) to prevent it being pinched by the junction box upper cover. H TSB #:20-01-017H-1 Page 13 of 14 SUBJECT: SUBJECT: 7. RECALL 188 – PCB RELAY BLOCK INSTALLATION Reconnect the negative (-) battery terminal. Connect the extension wiring (I) to the negative (-) battery cable terminal and tighten the nut (J). Tightening Torque: 19.6 ~ 29.4 Nm (2.0 ~ 3.0 kgf.m, 14.4 ~ 21.6 lb-ft) I J 8. Install the new junction box upper cover (K). 9. Start the engine. Confirm the “ABS”, “ESC” and “Brake” indicator lamps are not illuminated, clear any incidental DTCs and reprogram the customer’s radio preset stations. TSB #:20-01-017H-1 K Page 14 of 14 SUBJECT: