16-01-010

GROUP
CAMPAIGN
DATE
Technical Service Bulletin
SUBJECT:
MARCH 2016
NUMBER
16-01-010
MODEL(S)
Sonata (YF)
Elantra (MD)
INSTALLATION OF URETHANE PROTECTOR OVER FRONT COIL SPRINGS
(RECALL CAMPAIGN 133)
This bulletin supersedes TSB 15-01-049-2 to include additional information regarding:
a) warranty submission for replacement springs,
b) Sonata (YF) coil springs with brown urethane tubes.
 IMPORTANT
*** Retail Vehicles ***
Dealers must perform this Recall 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:
On certain 2011 Sonatas (YF) and Elantras (MD), corrosion can build up at the front coil springs,
resulting in possible fracture near the base. A fractured spring can make contact with the tire,
potentially resulting in a tire puncture and increasing the risk of a crash. This bulletin describes the
procedure to install urethane tubes over the front coil springs to prevent a tire puncture.
Applicable Vehicles:
 2011 model year Sonatas (YF), produced from DEC 11, 2009 to FEB 28, 2010
 2011 model year Elantras (MD), produced from NOV 12, 2010 to MAR 31, 2011
 Area: Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan,
Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island,
Vermont, West Virginia, Wisconsin, and the District of Columbia
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
RECALL 133 – URETHANE TUBE INSTALLATION
SUBJECT:
 IMPORTANT
There are circumstances under which vehicles not currently or never registered in a “salt belt” state
may be eligible for this Campaign. These circumstances include:
1. Vehicles that have relocated into a “salt belt” area and/or vehicles registered in a “non-salt
belt” state and driven in a “salt belt” area. If it is determined that an owner of a vehicle
within the affected VIN production date range relocates or has operated their vehicle in a
“salt belt” area, the dealer should perform the campaign procedure. The dealer should
perform this procedure at no cost to the customer, and Hyundai’s Warranty PA Center must
be contacted prior to repair and submission of the Warranty Claim.
2. Vehicles in “non-salt belt” states that exhibit corrosion damage. In the event that a vehicle
in a “non-salt belt” state exhibits corrosion damage, the dealer should perform the recall
procedure. This applies to both “salt-belt” and “non-salt belt” state dealers. The dealer
should perform this procedure at no cost to the customer, and Hyundai’s Warranty PA
Center must be contacted prior to repair and submission of the Warranty Claim.
 NOTE
If the owner of a vehicle within the affected VIN production date range requests an inspection of
their vehicle to check for a fractured spring, the inspection should be performed at no charge to the
customer.
Part Information:
Part Name
Model
Part Number
Remark
URETHANE
TUBE
Elantra (MD)
54631-3X000QQH
(2) Blue Tubes
Sonata (YF)
54631-3Q000QQH
(2) Yellow Tubes
NOTE: Each foil package contains a clear pouch with (2) urethane tubes.
CAUTION
Urethane tube use;
 Wear gloves and eye protection.
 The tubes can only be used if each length is over 330mm (13.0 inches).
 Install the tubes in a well ventilated area.
 The tubes will begin to contract after opening the packaging.
o Only remove one tube at a time before installation.
o Install the tubes immediately after opening the pouch.
 Keep unopened packages in a dark, cool place away from direct sunlight.
TSB #: 16-01-010
Page 2 of 9
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RECALL 133 – URETHANE TUBE INSTALLATION
SUBJECT:
Tool Information:
Name
Part Number
Remark
0K546-1H100QQH
Coil Spring Compressor (Jig) Set
Hyundai will provide one
(1) set to all dealers.*
HKL-MS930QQH
Henkel Teroson MS930 Sealant
Hyundai will provide one
(1) tube to all dealers.*
One (1) tube for 7 cars.
Dealer’s responsibility
Caulking Gun
*Additional product can be ordered from your facing PDC.
CAUTION
Sealant use:
 Wear gloves and eye protection.
 Discard by the “best before” date printed on the tube.
 Store in a cool, dark place.
Warranty Information:
Op Code
Operation
Op Time
51C079R0
Urethane tube installation [Both sides]
0.5 M/H
NOTE 1: Submit Claim on Campaign Claim Entry Screen.
NOTE 2: Reimbursement of sealer on each claim in sublet.
NOTE 3: If a part is found in need of replacement while performing Recall 133 and the affected
part is still under warranty, submit a separate claim using the same Repair Order. If
the affected part is out of warranty, submit a Prior Approval Request for goodwill
consideration prior to performing the work.
TSB #: 16-01-010
Page 3 of 9
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SUBJECT:
RECALL 133 – URETHANE TUBE INSTALLATION
Service Procedure:
Installation of Urethane Tubes for Both the Sonata (YF) and Elantra (MD)
1a.
Lift up the vehicle and then remove the front
wheels & tires (A).
Tightening torque:
88.2 ~ 107.8 Nm (9.0 ~ 11.0 kgf.m, 65.0 ~
79.5 Ib-ft)
CAUTION
Wear eye protection while performing spring
compression work.
1b.
A
Some Sonatas might have a brown
urethane tube installed on the spring.
 Carefully remove the tube without
damaging the black coating.
 Then perform the procedures in this
TSB.
TSB #: 16-01-010
Page 4 of 9
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2.
RECALL 133 – URETHANE TUBE INSTALLATION
On one side of the vehicle, install the coil
spring compressor jig (B1, B2) on opposite
sides of the spring as shown in the picture.
Compress the coil one side at a time. Do
not compress each side more than 25 mm
(1.0 in.) at a time.
B2
B1
CAUTION
Do not compress the spring more than 50 mm (2.0
in.).
 NOTE
Place the jig (B) on the spring to allow enough
clearance to completely slide on the tube.
B
B
3.
Move the bottom of the spring (C) over the
inside hump (D) of the lower spring seat
(E).
C
D
E
TSB #: 16-01-010
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SUBJECT:
4a.
RECALL 133 – URETHANE TUBE INSTALLATION
Use an air nozzle to remove any debris
from around the lower spring seat.
-Clean the lower portion of the spring where
the urethane tube will be installed.
-Inspect the lower coils of the spring for
damage or corrosion. Replace as
necessary. If the spring is still under
warranty, submit a separate claim using the
same Repair Order. If the spring is out of
warranty, submit a Prior Approval Request
for goodwill consideration prior to
performing the work.
4b.
5.
If a Sonata is in need of a replacement
spring, P/N 54630-3Q010, the spring might
have a brown urethane tube installed.
 Carefully remove the brown urethane
tube without damaging the black
coating.
 Install the yellow urethane tube, P/N
54631-3Q000QQH, onto the
replacement spring as described in
this TSB.
 Remove the spring from the vehicle
according to the applicable workshop
manual.
 Install the replacement spring into
the vehicle according to the
applicable workshop manual.
Carefully pull the rubber spring pad (F) off
the lower spring seat.
-Clean the top (F) and bottom (G) surfaces
of the rubber spring pad.
F
-Clean the lower spring seat (E).
G
E
TSB #: 16-01-010
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6.
RECALL 133 – URETHANE TUBE INSTALLATION
Apply a bead of sealant in between the pad
and the lower spring seat as shown by line.
(H).
 NOTE
Sealant must be discarded by the “best before”
date printed on the tube.
7.
H
Return the rubber spring pad to its original
position. Carefully pull rubber pins (I) back
through their respective holes in the lower
spring seat.
I
8.
Select the appropriate tube for the model.
*BLUE: Elantra (MD)
*YELLOW: Sonata (YF)
Unpack the urethane tube.
CAUTION
Urethane tube use;
 Wear gloves and eye protection.
 The tubes can only be used if each length is over 330mm (13.0 inches).
 Install the tubes in a well ventilated area.
 The tubes will begin to contract after opening the packaging.
o Only remove one tube at a time before installation.
o Install the tubes immediately after opening the pouch.
 Keep unopened packages in a dark, cool place away from direct sunlight.
TSB #: 16-01-010
Page 7 of 9
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9.
RECALL 133 – URETHANE TUBE INSTALLATION
Locate arrow at one end of the tube (J).
Fill the tube with sealant from the end with
the arrow, until it reaches approximately
30 mm (1.20 in.) or to the square openings
(K).
10.
J
K
30 mm (1.20 in.)
Starting from the end with the arrow (I),
slide the urethane tube over the end of the
coil spring until the end of the tube (L)
aligns with the end of the spring.
I
L
TSB #: 16-01-010
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11.
RECALL 133 – URETHANE TUBE INSTALLATION
Carefully decompress the springs, making
sure the spring is properly engaged with
upper and lower spring seats on the strut.
The end of the spring should line up against
the lower spring seat guide (M).
Ensure the tube does not slide out of
position while decompressing the springs.
 NOTE
Decompress each side of the spring no more than
25mm (1.0 in.) at a time.
CAUTION


12.
Confirm the coil spring is properly engaged with
the strut at the upper and lower spring seats. If
it is out of position, compress the spring again
and realign.
Confirm the tube did not slide out of position. If
it is out of position, compress the spring again
and realign.
M
Perform the same procedure on the other
side.
Reinstall the tires & wheels.
TSB #: 16-01-010
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