2024 Hyundai Tucson EGR Valve Electrical Short TSB

Symptoms

Owners of affected 2024 Hyundai Tucson and Sonata vehicles may experience a "Malfunction Indicator lamp (MIL) illumination" on their dashboard. This warning light indicates a potential issue with the vehicle's emissions system or engine performance. The underlying cause for the 2024 Hyundai Tucson EGR valve electrical short is contamination during manufacturing.

Fault Codes / DTCs

An electrical short within the EGR valve assembly can trigger several diagnostic trouble codes (DTCs). These codes indicate specific malfunctions related to the EGR system or associated components.

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

Diagnosis and Trigger Conditions

The root cause of this issue is solder flux contamination within a sensor inside the EGR valve assembly during manufacturing. This contamination can lead to an electrical short, which then causes the EGR valve to malfunction. This malfunction triggers the "Malfunction Indicator lamp (MIL) illumination" and logs the associated DTCs. The California Air Resources Board (CARB) has determined that this condition may cause vehicles to release air pollutants exceeding federal and California standards.

Important Warnings and What Owners Should Know

Hyundai has outlined several critical points for owners and dealers regarding this service campaign:

• Mandatory Replacement: All affected vehicles will require replacement of the EGR valve assembly and gaskets. This is a 100% replacement campaign.
• Emissions Sticker: Every vehicle must have an emission sticker included under the hood after the inspection and repair.
• Proof of Correction Card: For vehicles registered in certain states (CA, CO, CT, DE, ME, MD, MA, NJ, NY, OR, PA, RI, VT, WA), a "Vehicle Emission Recall - Proof of Correction Card" (part number NP050-09006) will be provided. This card serves as verification that the repair has been completed and may be required for vehicle registration renewal.
• Owner Notification: Customers will be notified of this campaign via First Class Mail in October 2024.
• Emissions Inspection: Failure to complete this service could cause your vehicle to fail an emissions inspection (SMOG check) in states where required, and may be considered a lack of proper maintenance.

Repair Procedure Summary

The repair for the 2024 Hyundai Tucson EGR valve electrical short involves replacing the entire EGR valve assembly and its associated gasket. This procedure is detailed in Technical Service Bulletin (TSB) 24-01-080H. Dealers are instructed to refer to this TSB for the complete repair steps. The repair must be performed by a Hyundai Expert-certified technician or higher. The service is provided at no charge to the customer.

Required Parts

To perform the repair, specific parts are required. The main components are the EGR valve assembly and gasket. The following part numbers are associated with this campaign and require a valid campaign 9B3 VIN for ordering:

• 28400-2J310QQH
• 28400-25000QQH
• 28492-2J000QQH
• 28493-2S040QQH
• 28751-2S001QQH
• 28751-2S002QQH
• 28493-2S030QQH
• 39180-25000QQH

Additionally, a Campaign Sticker (NP001-SC9B3) and, for specific states, a Vehicle Emission Recall - Proof of Correction Card (NP050-09006) are required.

Warranty Information

Hyundai Service Campaign 9B3 covers the labor and parts for this repair. Dealers will be reimbursed for the following:

• Labor:
  • 0.5 M/H for Sonata Hybrid (EGR Valve Assembly/Gasket Replacement)
  • 2.4 M/H for Sonata (EGR Valve Assembly/Gasket Replacement)
  • 2.5 M/H for Tucson (EGR Valve Assembly/Gasket Replacement)
• Parts: Reimbursement for the EGR valve assembly and EGR pipe (all models). For Tucson/Sonata models only, reimbursement also includes the Crankshaft Position Sensor (CKPS), EGR Service Kit, and coolant (5 quarts for Sonata, 6 for Tucson).

Dealers are also required to take a photo of the newly installed EGR valve, capturing the production stamp with the last 6 digits of the VIN and the date of repair on a piece of paper.

Alternative Transportation

Hyundai recommends providing a Service Rental Vehicle (SRC) to customers if their vehicle needs to be kept overnight for the repair. Alternative transportation, such as a 3rd party rental or rideshare, may also be offered if an SRC is unavailable or if the repair procedure duration necessitates it.

Owner Action

If you own a 2024 Hyundai Tucson or Sonata, you will receive a notification letter by First Class Mail in October 2024 regarding Service Campaign 9B3. Once notified, it is important to schedule an appointment with your authorized Hyundai dealer to have the EGR valve assembly and gasket replaced. This repair will be performed free of charge. If you reside in a state requiring a "Proof of Correction Card," ensure you receive and retain it for your records.

NHTSA ID: 11008136