2024 Hyundai Tucson/Sonata EGR Valve Electrical Short

Hyundai has launched Service Campaign 9B3 to address a potential manufacturing defect in the exhaust gas recirculation (EGR) valve assembly in certain 2024 Hyundai Tucson and Sonata vehicles. This issue, stemming from solder flux contamination during production, can lead to an electrical short within the EGR valve. The Hyundai EGR valve electrical short can cause the Malfunction Indicator Lamp (MIL) to illuminate and may result in the vehicle exceeding Federal and California emissions standards.

Symptoms

Owners of affected vehicles may notice the Malfunction Indicator Lamp (MIL) illuminating on the dashboard. This light indicates a potential issue with the vehicle's emissions system or engine performance. The underlying cause is the Hyundai EGR valve electrical short.

Fault Codes / DTCs

An electrical short in the EGR valve assembly can trigger specific Diagnostic Trouble Codes (DTCs) that will be stored in the vehicle's computer. These codes include:

• P0405
• P0642
• P0652
• P0404
• P049D
• P240F

These codes indicate a malfunction in the EGR system, often related to circuit issues or performance.

Diagnosis / Trigger Conditions

The root cause of this issue is a sensor within the EGR valve assembly that was contaminated with solder flux during manufacturing. This contamination can lead to an electrical short, which then causes the EGR valve to malfunction. The electrical short can also affect the crank position sensor, as both components share the same power circuit. This condition triggers the Malfunction Indicator Lamp (MIL) and sets the associated DTCs.

Repair Procedure Summary

To resolve the Hyundai EGR valve electrical short, dealers will replace the EGR valve assembly and gasket. This repair is outlined in Technical Service Bulletin (TSB) 25-01-023H, which supersedes previous versions and includes updated information for Sonata and Tucson models. The procedure requires a Hyundai Expert-level technician or higher. As part of the repair, a photo of the newly installed EGR valve, showing the production stamp and the last six digits of the VIN, along with the repair date, must be taken for documentation.

Required Tools or Parts

The following parts may be required for the repair, depending on the specific vehicle model:

• EGR Valve Assembly and Gasket (various part numbers including 28400-2J310QQH, 28400-25000QQH, 28492-2J000QQH, 28493-2S040QQH, 28751-2S001QQH, 28751-2S002QQH, 28493-2S030QQH)
• EGR Service Kit (for Tucson/Sonata models only)
• Coolant (5 quarts for Sonata, 6 quarts for Tucson)
• Campaign Sticker (Part Number: NP001-SC9B3)
• Vehicle Emission Recall - Proof of Correction Card (Part Number: NP050-09006)

Important Owner Information

Owners should be aware of several key points regarding this service campaign:

• "All vehicles will require replacement of the EGR valve & gaskets are 100%." This means every affected vehicle will undergo this repair.
• "Every vehicle needs to have an emission sticker under the hood included after the inspection." This sticker confirms the emissions-related repair has been completed.
• "A proof of correction card will also need to be provided to affected vehicles in certain states." This card is crucial for owners in states like California, Colorado, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Jersey, New York, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, as it serves as verification for vehicle registration renewal.
• "Failure to have this service performed could cause your vehicle to fail an emissions inspection (SMOG check) when required under state law. It could also be considered a lack of proper maintenance." Completing this repair is essential for compliance and vehicle longevity.

Customers were notified via First Class Mail in October 2024.

Owner Action

If you own a 2024 Hyundai Tucson or Sonata, you should contact your authorized Hyundai dealer to schedule an appointment for Service Campaign 9B3. The repair for the Hyundai EGR valve electrical short will be performed free of charge. If your vehicle needs to be kept overnight or if the repair is lengthy, alternative transportation options such as a Service Rental Vehicle (SRC) or a third-party rental may be provided by the dealer.

NHTSA ID: 11015668