TSB-15-01-031

SB-10058910-5027
GROUP
NUMBER
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
JULY 2015
15-01-031
MODEL(S)
3.3L SANTA FE (CM)
CYLINDER HEAD COVER OIL LEAK REPAIR
(SERVICE CAMPAIGN 936)
 IMPORTANT
*** Retail Vehicles ***
Dealers must perform this Service Campaign whenever an affected vehicle is in the shop for any
maintenance or repair.
When a vehicle arrives at the Service Department, access Hyundai Motor America's "Warranty
Vehicle Information" screen via WEBDCS to identify open Campaigns.
Description: This bulletin outlines the following service procedures.
 Replace the LH (front) cylinder head cover gasket.
 Inspect the alternator for signs of oil contamination.
 Replace the alternator if any oil contamination is found.
An oil contaminated alternator may result in low or no alternator output, which may cause charging
system warning light illumination, no crank, no start, or a loss of power. If the vehicle continues to be
driven with the charging system warning light illuminated, the engine may stop running.
Applicable Vehicles: 2007-09MY SANTA FE 3.3L
Parts Information:
Part Name
Part Number
Qty.
Gasket - Rocker Cover LH
22453-3C120-QQH
1
Generator Assembly
37300-3C250-QQH
* (See below NOTE)
*NOTE: Replacement is required only if it does not pass the visual inspection for oil contamination.
Denso alternator P/N 37300-3C120 can be replaced with Valeo alternator 37300-3C250-QQH.
Additional Materials:
Product Name
Gray Liquid RTV Gasket
Warranty Information:
Op Code
Part Number
00232-19061 (or equivalent to TB1217H)
Operation
Op. Time
50CA07R0
CYLINDER HEAD COVER GASKET REPLACEMENT
AND ALTERNATOR INSPECTION
1.1
50CA07R1
CYLINDER HEAD COVER GASKET REPLACEMENT
AND ALTERNATOR REPLACEMENT
2.2
NOTE: Submit Claim on Campaign Claim Entry Screen
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
Service Procedure:
* Perform the service procedure referring to the flow chart below.
Clean cylinder head cover
and replace the gasket.
Visually inspect alternator
for oil contamination.
No
Yes
Alternator is oil
contaminated?
Replace Alternator
Done
Done
Cylinder Head Cover Gasket Replacement
1.
Remove the engine cover (A).
A
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
2.
Remove the upper mounting bracket bolt (B)
near the OCV connector.
3.
Remove the lower mounting bracket bolt (C)
near the B2S1 oxygen sensor connector.
B
C
4.
5.
Disconnect the bank 2 ignition coil connectors
(D), and remove the ground (E), and then
remove the wiring harness protector (F).
F
G
Disconnect the bank 2 Camshaft Position
Sensor (CMPS) at (G).
E
D
6.
D
D
Remove the hose (H) and disconnect harness
connectors (I) from the bank 2 fuel injectors.
I
I
I
H
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SUBJECT:
CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
7.
Unlock the terminal cable clips (J).
8.
Remove alternator “B” terminal cable mounting
bracket bolts (K) and then remove the wire
bracket bolts (L).
J
L
K
9.
J
Remove the bank 2 ignition coils (M).
M
M
M
10. Remove the bank 2 (LH) cylinder head cover
(N).
Tightening torque specification:
8.0 lb-ft (96 lb-in, 10.8 Nm)
N
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
NOTICE
Carefully remove the cylinder head cover to avoid any dirt/debris falling into
the engine. Debris falling into the cylinder head can result in engine damage.
11. Remove all remaining liquid gasket residue
(including outside area of the cylinder head and
chain cover as shown in the picture below).
NOTICE


Be careful not to damage the surface of
the cylinder head cover.
The removed liquid gasket residue
should not fall into the engine.
12. Clean the cylinder head and cover with a clean
lint-free shop towel referring to the picture of the
cleaning area below (highlighted in red).
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SUBJECT:
CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
13. With a degreaser/cleaner (O), clean off any of
the remaining dirt and oil from the cylinder head
and cover. Then wipe dry with a clean lint-free
shop towel.
O
14. Remove the cylinder head cover gasket (P).
P
15. Install the new cylinder head cover gasket (Q).
NOTICE
Before installing the new gasket (Q),
clean the gasket installing groove with a
degreaser/cleaner and a clean lint-free
shop towel.
Q
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
16. Apply liquid RTV gasket onto the “T” joints (R),
which are the mating points where the front
timing chain cover and the cylinder head meet.
NOTICE
When applying the liquid RTV gasket,
the applied bead on the surface should
be approximately 3/16th in (4.5 mm) wide
as shown in the picture below.
R
Carefully reinstall the cylinder head cover within
the next several minutes before the liquid RTV
gasket begins to harden.
R
Tightening torque specification:
8.0 lb-ft (96 lb-in, 10.8 Nm
NOTICE
When reinstalling the cylinder head
cover, tighten the bolts in the order as
shown in the picture at right.
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SUBJECT:
CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
17. Apply liquid RTV gasket onto the outer surface
of the “T” joints (S) of the cylinder head and
cover.

Apply the liquid RTV gasket in a line at least
30 mm long, following the green bold line as
shown in the picture on the right and below.
S
30 mm

Within several minutes before the liquid RTV
gasket begins to harden, spread the gasket
evenly as shown in the picture on the right.
18. Reinstall all the removed parts in the reverse
order of removal.
NOTICE
Allow at least one hour for the liquid RTV gasket to cure before starting the engine.
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
ALTERNATOR INSPECTION
Visually inspect the alternator for presence of
any level of oil contamination due to oil leakage
that may have occurred from the rocker cover.

If ANY level of oil contamination is found
inside or on the exterior of the alternator,
then the alternator must be replaced using
the service procedure outlined in the
following pages.
Inspect for oil contamination of
Alternator
Example: Oil Contamination  Replace Alternator
NOTICE
The example shown has a high level of
oil contamination on the alternator, but
ANY level of oil contamination found
outside or inside the alternator requires
replacement of the alternator.

If NO oil contamination is found anywhere
on the exterior or inside the alternator, then
the service procedure is complete.
Example: No Oil Contamination  Good Alternator
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SUBJECT:
CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
ALTERNATOR REPLACEMENT
1.
Remove the air duct (A).
A
2.
Record the customer’s radio stations.
Disconnect the battery (B) and make note of
customer radio presets to program back later.
B
3.
Loosen the battery tray mounting fasteners and
remove the battery tray (C).
NOTICE
Set aside the removed battery tray (C) to
a safe area so that it does not interfere
during the alternator removal process.
TSB #: 15-01-936
C
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
4.
Disconnect the LH fan motor connector (D).
D
5.
Remove the LH fan shroud bolts (E).
Tightening torque specification:
5.0 lb-ft (60 lb-in, 6.8 Nm)
E
E
6.
Remove the LH fan shroud (F).
NOTICE
Carefully remove the LH fan shroud (F)
so that it does not damage any
surrounding parts.
F
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SUBJECT:
7.
CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
Disconnect the RH fan motor connector (G).
G
8.
Remove the RH fan shroud bolts (H).
Tightening torque specification:
6.5 lb-ft (78 lb-in, 8.8 Nm)
H
9.
H
Move the RH fan shroud (I) about 12 inches
towards the driver’s side of the vehicle (as
shown by the orange arrow) to provide enough
working space to remove and replace the
alternator.
I
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12
in
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10. Remove the alternator upper mounting bolt (J).
Tightening torque specification:
22 lb-ft (29.8 Nm)
J
11. Remove the RH front wheel and tire by
loosening the 5 wheel nuts (K).
Tightening torque specification:
75 lb-ft (101.7 Nm)
K
11. Remove the RH engine side cover (L).
L
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CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
12. Remove the undercover (M).
M
13. Disconnect the connector (N) from the A/C
compressor.
N
14. Remove the alternator connector and the B+
terminal (O).
O
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 936)
15. Remove the drive belt after relaxing the belt
tension by rotating the tensioner pivot bolt (P).
P
16. Remove the alternator lower mounting bolt (Q).
Tightening torque specification:
22 lb-ft (29.8 Nm)
Q
17. Remove the alternator (R).
R
18. Install the replacement alternator in the reverse
order of removal.
19. Verify repair and reset the customer’s radio
stations.
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SUBJECT:
TO:
Hyundai Dealership General Managers, Sales Managers,
Service Managers, Parts Managers, and Warranty
Administrators
FROM: Hyundai Motor America
DATE: August 27, 2015
SUBJECT: Service Campaign 936: 2007-09 Santa Fe Cylinder Head
Cover Oil Leak Repair(TSB# 15-01-031)
Hyundai Motor America is conducting a Service Campaign to inspect
for a valve cover oil leak on certain 2007 - 2009 3.3L Santa Fe
vehicles.
Technical Service Bulletin #15-01-031 provides the details of
the service procedure to replace the valve cover gasket and
inspect the alternator for oil contamination (and replace if
necessary).
In order to identify only those vehicles affected by Service
Campaign 936, it will be necessary to access Hyundai Motor
America’s “Warranty Vehicle Information” screen via WEBDCS before
starting the repair. The “Warranty Vehicle Information” screen
will identify affected vehicles with an open Service Campaign
936.
A listing of VEHICLES is also located on WEBDCS, SERVICE tab,
select INFORMATION, and select UNCOMPLETED CAMPAIGN VIN LISTING –
RETAILED.
TSB #15-01-031 will be available on Hyundai’s Service Website on
August 27, 20154. It contains instructions on performing the
service and submitting the service campaign claim.
An initial shipment of Cylinder Head Gaskets (LH) and Alternators
began shipping on August 27, 2015 to dealers in their weekly
parts shipment. Additional parts can be ordered following the
standard parts ordering procedure.
It is IMPORTANT TO SUBMIT A SERVICE CAMPAIGN CLAIM FOR EACH
VEHICLE SERVICED so your dealership can be compensated for your
work and Hyundai can maintain accurate records of campaign
completions.
LEGAL LIABILITY NOTICE: You are required to keep confidential
any and all information and documents provided to you by Hyundai
Motor America in the conduct of carrying out work for this recall
campaign. Hyundai Motor America dealers may use owner
information provided for the campaign only for the purpose of
conducting and performing this recall campaign, and for no other
purpose.
Hyundai appreciates your cooperation and support. Questions may
be directed to your District Parts and Service Manager or
Warranty HELPREP line at 1-877-446-2922.
HYUNDAI MOTOR AMERICA