5NP-D5E6F-12

GROUP
CAMPAIGN
Technical Service Bulletin
SUBJECT:
DATE
NOVEMBER 2016
NUMBER
16-01-050
MODEL(S)
Sonata (LFa)
TOP ALTERNATOR MOUNTING BOLT REPLACEMENT (SERVICE CAMPAIGN TTT)
 IMPORTANT
*** Dealer Stock and 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: Certain Sonata vehicles equipped with the 1.6L Turbo engine have a manual alternator
belt tensioner system. The top alternator mounting bolt (A in the diagram) may break over time if it is
tightened over specification and could result in illumination of the battery warning light and/or the
engine overheating in some cases. This bulletin describes the procedure to replace the top alternator
mounting bolt.
Applicable Vehicles:
2015-2017 MY Sonata (LFa) vehicles equipped with the 1.6L Turbo engine
Part Information:
Part Name
Part Number
Qty.
BOLT
11405-08406-K
1
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
TOP ALTERNATOR MOUNTING BOLT REPLACEMENT (SERVICE CAMPAIGN TTT)
Warranty Information:
Op Code
Operation
Op Time
60CA22R0
Bolt replacement
0.3 M/H
NOTE 1: Submit Claim on Campaign Claim Entry Screen
NOTE 2: If a part is found in need of replacement while performing Service Campaign TTT 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.
NOTICE
Ensure the vehicle is in Park, the key or key fob is removed from the vehicle, and the
parking brake is set.
!
CAUTION
Ensure the engine is cool before any work is performed as the engine compartment
temperature is high after vehicle operation and could cause physical injury.
Service Procedure:
1.
Locate the belt tensioner on the alternator.
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SUBJECT:
TOP ALTERNATOR MOUNTING BOLT REPLACEMENT (SERVICE CAMPAIGN TTT)
2.
Mark the threads at the location shown for
reference later.
3.
Loosen the top alternator mounting bolt.
4.
Loosen the bottom alternator bolt.
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TOP ALTERNATOR MOUNTING BOLT REPLACEMENT (SERVICE CAMPAIGN TTT)
5.
Loosen the tension on the belt.
6.
Remove the top alternator mounting bolt.
7.
Replace with a new bolt. Do not tighten
fully.
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SUBJECT:
TOP ALTERNATOR MOUNTING BOLT REPLACEMENT (SERVICE CAMPAIGN TTT)
8.
Tighten the belt tensioner bolt back to the
original mark on the threads from Step 2.
9.
Verify the belt has the proper tension and adjust it if needed.
!
CAUTION
Do not overtighten the alternator mounting bolts. Overtightening could lead to premature
bolt breakage.
10.
After the belt tension has been properly adjusted, tighten the top alternator mounting bolt.
Torque: 26.5 ~ 37.3 Nm (19.5 ~ 27.5 lb-ft)
11.
Tighten the bottom alternator bolt.
Torque: 29.4 ~ 41.2 Nm (21.7 ~ 30.4 lb-ft)
12.
Start and run the engine to ensure proper operation.
TSB #: 16-01-050
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