2024 Hyundai Tucson / Sonata EGR Valve Fault (9B3)

Hyundai has launched Service Campaign 9B3, documented in Technical Service Bulletin (TSB) 24-01-080H, to address a potential issue with the exhaust gas recirculation (EGR) valve assembly in certain 2024 Hyundai Tucson and Sonata vehicles. This campaign is crucial for owners experiencing a Malfunction Indicator Lamp (MIL) illumination or specific diagnostic trouble codes (DTCs) related to the EGR system.

The core problem stems from manufacturing contamination where solder flux may have affected the EGR valve assembly sensor. This can result in an electrical short, directly impacting the proper function of the EGR system and leading to the illumination of the MIL, commonly known as the 'Check Engine' light. This issue specifically affects 2024 Hyundai Tucson (NX4) models equipped with the Theta 2.5 GDI engine, produced between January 17, 2024, and February 22, 2024. It also impacts 2024 Hyundai Sonata (DN8) models with the Theta 2.5 GDI engine, produced from February 6, 2024, to February 16, 2024, and 2024 Hyundai Sonata Hybrid (DN8 HEV) models with the Nu 2.0 GDI engine, produced between February 6, 2024, and February 24, 2024. Owners of an affected 2024 Hyundai Tucson EGR valve fault should have their vehicle inspected.

Symptoms

Owners of affected vehicles may notice the following symptom:

• Malfunction Indicator Lamp (MIL) illumination on the dashboard.

This warning light indicates a problem with the vehicle's emissions control system, often accompanied by specific diagnostic trouble codes.

Fault Codes / DTCs

When the Malfunction Indicator Lamp (MIL) illuminates due to this EGR valve issue, the following diagnostic trouble codes (DTCs) may be stored in the vehicle's computer:

Code	Description
P0405	Exhaust Gas Recirculation Sensor A Circuit Low
P0642	Sensor Reference Voltage A Circuit Low
P0652	Sensor Reference Voltage B Circuit Low
P0404	Exhaust Gas Recirculation Control Circuit Range/Performance
P049D	Exhaust Gas Recirculation 'A' Control Position Exceeded Learning Limit
P240F	Exhaust Gas Recirculation 'A' Control Stuck Open

These codes indicate various electrical or performance issues within the EGR system, directly related to the potential electrical short caused by solder flux contamination. If you have a 2024 Hyundai Tucson EGR valve fault, these are the codes you might see.

Diagnosis / Trigger Conditions

The root cause of this issue is a manufacturing defect where solder flux contaminates the sensor within the EGR valve assembly. This contamination can lead to an electrical short, which then triggers the Malfunction Indicator Lamp (MIL) and stores the associated DTCs. The condition is present in specific production batches of the 2024 Hyundai Tucson and Sonata models, as detailed in TSB 24-01-080H.

Important Warnings

Hyundai has issued specific instructions for technicians during this service campaign:

• Do NOT use if damaged: If the EGR control valve is damaged during removal or handling, it must not be reused. Using a damaged part will not resolve the issue.
• Do NOT reuse the EGR cooler gasket: When replacing the EGR cooler, the old gasket must be discarded and a new one installed to ensure a proper seal and prevent future leaks.

Repair Procedure Summary

The repair procedure outlined in Service Campaign 9B3 (TSB 24-01-080H) involves replacing the EGR valve assembly and gasket. The steps vary slightly between the Sonata Hybrid and the Sonata/Tucson models, with the latter requiring a more extensive process.

For Sonata Hybrid (DN8 HEV) models, the procedure includes:

1. Disconnecting the high-voltage circuit and the 12V positive connector from the auxiliary battery.
2. Waiting at least 3 minutes to ensure the high voltage system capacitor is discharged.
3. Loosening mounting clamps and removing the air intake hose.
4. Disconnecting the EGR control valve connector.
5. Removing mounting nuts from the EGR valve cooler pipe.
6. Removing mounting bolts and the EGR valve itself.

For Sonata (DN8) and Tucson (NX4) models, the procedure is more involved and includes:

1. Disconnecting the negative (-) battery terminal.
2. Removing the engine cover, air duct, and air cleaner assembly.
3. Removing the battery and battery tray.
4. Lifting the vehicle and removing the engine room undercover.
5. Draining the coolant by removing the drain plug.
6. Removing the heat protector and front muffler along with its hanger.
7. Removing the water inlet pipe and exhaust manifold.
8. Removing the EGR cooler, ensuring to discard the old gasket.
9. Removing the Crank Position Sensor (CKPS).
10. Removing the Integrated Thermal Management Module (ITM) and EGR cooler pipe.
11. Disconnecting the EGR control valve connector.

For all models, the new EGR valve assembly and gasket are then installed, with specific tightening torques applied to various components. For example, the EGR control valve mounting nuts require 16 lb-ft (22 N.m) of torque. Technicians are required to take specific photos of the newly installed parts, VIN, and date of repair for documentation purposes (STUI process).

Required Tools or Parts

To perform this repair, Hyundai specifies the following parts:

• Campaign Sticker: NP001-SC9B3
• Vehicle Emission Recall - Proof of Correction Card: NP050-09006
• EGR Valve Assembly (Sonata Hybrid DN8 HEV): 28400-2J310QQH
• Gasket - EGR Pipe (Sonata Hybrid DN8 HEV): 28492-2J000QQH
• EGR Valve Assembly (Sonata DN8 & Tucson NX4): 28400-2S000QQH
• Gasket - EGR Pipe (in) (Sonata DN8 & Tucson NX4): 28493-2S040QQH
• Gasket - EGR Pipe (out) (Sonata DN8 & Tucson NX4): 28493-2S030QQH
• Crankshaft Position Sensor (CKPS) (Sonata DN8 & Tucson NX4): 39180-2S000QQH
• Coolant (1 Quart): 00232-19098WAR (Note: 5 quarts for Sonata, 6 for Tucson, to be diluted to 45-60% coolant with water).
• EGR Service Kit (Sonata DN8): 28751-2S001QQH (includes various gaskets: 28751-D4350, 28751-3S100, 28493-2S010, 28493-2S020, 28535-2SAD0, 25623-2S600, 25462-2S000, 25462-2S500, 28493-2S000, 28493-2S050)
• EGR Service Kit (Tucson NX4): 28751-2S002QQH (includes various gaskets: 28751-3S100, 28751-2S000, 28493-2S010, 28493-2S020, 28535-2SAD0, 25623-2S600, 25462-2S000, 25462-2S500, 28493-2S000, 28493-2S050)

Owner Action

If you own a 2024 Hyundai Tucson or Sonata and experience a Malfunction Indicator Lamp (MIL) illumination, especially with the DTCs mentioned, it is recommended to contact your authorized Hyundai dealer. This is a service campaign (9B3), meaning dealers must perform this service on all affected vehicles prior to customer retail delivery and whenever an affected vehicle is in the shop for any maintenance or repair. The repair will be performed free of charge.

Vehicle Emission Recall - Proof of Correction Card

For vehicles registered in California, Colorado, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Jersey, New York, Oregon, Pennsylvania, Rhode Island, Vermont, and Washington, a Vehicle Emission Recall - Proof of Correction card must be completed. This card serves as evidence of voluntary service campaign completion and may be required for vehicle registration renewal. The dealership's service manager will complete this card using permanent ink and provide it to the owner upon completion of the campaign.

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Source: NHTSA ID: 11008137