2024 Hyundai Elantra Coolant Leak from ITM Module TSB 25-EM-003H

Certain 2024 Hyundai Elantra vehicles equipped with a 2.0L engine may develop a Hyundai Elantra coolant leak from the Heat Exchange Port located on the Integrated Thermal Management (ITM) Module assembly. This issue is addressed by Hyundai Technical Service Bulletin (TSB) 25-EM-003H, which supersedes a previous bulletin (24-EM-011H) to expand the affected production date range and update warranty information.

Symptoms

Owners of affected vehicles may notice a Hyundai Elantra coolant leak originating from the Heat Exchange Port of the Integrated Thermal Management (ITM) Module assembly. This could lead to visible coolant puddles under the vehicle or a drop in coolant levels.

Repair Procedure Summary

The repair involves replacing the Heat Exchange Port at the ITM assembly. The procedure includes several steps:

1. ITM Module Removal: The Integrated Thermal Management (ITM) Module is carefully removed from the vehicle. Technicians are instructed to use a supplied funnel and coolant recovery container to drain and reuse the coolant, preventing contamination.
2. Heat Exchange Port Replacement: The insulation cap is installed on the ITM actuator connector. Fixing screw bolts are loosened and removed from the heat exchange port. The port is then detached from its housing. The tightening torque for these bolts is 4.4 lb-ft (53 lb-in or 5.9 N.m).
3. Component Disassembly: The Teflon gasket, support, and wave spring are removed in a specific order. The Teflon gasket and Heat Exchange Port (including its O-ring) are replaced, while the support and wave spring are reused. It is crucial to ensure the marking on the new Teflon gasket faces downward during reinstallation.
4. Reassembly: When installing the O-ring onto the ITM housing, it must be coated entirely with coolant. The new and old Heat Exchange Ports are photographed side-by-side with the last 6 digits of the VIN and the repair date for