2021-2023 Hyundai Engine Replacement Guidelines TSB 22-EM-010H

Hyundai has issued Technical Service Bulletin (TSB) 22-EM-010H to provide detailed guidelines for technicians performing engine short block or sub-assembly replacements. These guidelines are crucial for inspecting, cleaning, or replacing specific components within the engine's intake and exhaust systems. The primary goal of TSB 22-EM-010H is to ensure the longevity and proper function of the new engine assembly by addressing potential sources of reoccurring damage.

This bulletin, dated July 2022, applies to all engine-equipped Hyundai models, including the 2021-2023 Hyundai Tucson, Elantra, Accent, Palisade, Kona, Venue, Santa Cruz, Santa Fe, Sonata, and Veloster. It supersedes previous TSB 17-EM-001, introducing updated criteria specifically for intake manifold replacement.

Important Warnings

Hyundai emphasizes that failure to follow the instructions outlined in TSB 22-EM-010H can lead to reoccurring damage to the newly installed engine assembly. This highlights the critical importance of adhering to these inspection and replacement procedures. For additional information regarding engine oil pump replacement during an engine swap, technicians are directed to refer to TSB 10-EM-003 (ENGINE OIL PUMP REPLACEMENT GUIDELINES DURING ENGINE REPLACEMENT).

Engine Conditions Requiring Inspection

The TSB identifies two primary engine conditions that necessitate specific inspection and service actions for intake and exhaust system components when performing a Hyundai engine replacement:

1. Any physical damage to one or more combustion chambers, valves, cylinder walls, and/or piston tops due to internal engine issue. This includes severe internal engine damage such as broken pistons or valves, connecting rod interference with the cylinder block, a seized crankshaft, or large debris/fragments found in the oil pan.
2. Engine oil consumption and/or excessive combustion blow by due to reduced seal between cylinder walls and piston rings. This condition indicates a problem with the engine's sealing capabilities.

Recommended Inspection and Replacement Actions

Depending on the engine condition, specific actions are required for various components to ensure the new engine's integrity. These guidelines are central to preventing further issues after a Hyundai engine replacement.

For Physical Internal Engine Damage

If severe physical internal engine damage is observed, the following actions are recommended for the associated components:

• MUST REPLACE: The Intake Manifold and the Engine Oil Pump/Balance Shaft Module must be replaced. Specifically, if severe physical internal engine damage is observed, the intake manifold and oil pump/BSM must not be reused. These components should be replaced if they are not supplied with the replacement engine.
• REPLACE if debris is found inside: The Air Intake Filter, Air Intake Carbon Trap (if equipped), Intercooler (if equipped), and Exhaust Manifold with Catalyst Assembly should be replaced if debris is found within them.
• Inspect and CLEAN (Replace if damaged or debris is stuck): The Throttle body, PCV System / Valve Cover Baffle, Air Intake Hose / Pipe, MAF Sensor, Exhaust Manifold (Non-Catalyst Type), Intercooler Pipe (if equipped), and Turbocharger (if equipped) must be inspected. These components should be cleaned thoroughly using an appropriate cleaning agent, ensuring all residual liquids are drained and dried with shop air. If any debris remains stuck or the component is damaged, it must be replaced.

For Engine Oil Consumption and/or Excessive Blow By

When engine oil consumption or excessive combustion blow by is the primary concern, the following components require specific attention:

• Inspect and CLEAN: The Intake Manifold, Throttle Body, PCV System / Valve Cover Baffle, Air Intake Hose / Pipe, Intercooler Pipe (if equipped), and Intercooler (if equipped) should be inspected and cleaned. Similar to the previous condition, cleaning should be thorough, and replacement is necessary if damage or stubborn debris prevents effective cleaning.

Warranty Information

Hyundai states that normal warranty applies to the procedures outlined in TSB 22-EM-010H. Owners should consult their dealership for specific warranty coverage details related to these inspections and repairs.

Service Procedure

This TSB provides the guidelines for component inspection and replacement but directs technicians to refer to the applicable Shop Manual for the detailed service procedures required to perform these actions correctly during a Hyundai engine replacement.

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Source: NHTSA ID: 10217251