5NP-U6Y5P-01

GROUP
NUMBER
17-01-045-2
CAMPAIGN
DATE
Technical Service Bulletin
SUBJECT:
MODEL
DECEMBER, 2017
SONATA
(LF HEV/ LF PHEV)
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT
(Service Campaign T2E)
This bulletin revises TSB# 17-01-045-1 to add Sonata Plug-in Hybrid (PHEV) vehicles.
 IMPORTANT
*** Dealer Stock and Retail Vehicles ***
Dealers must perform this Service Campaign on all affected vehicles prior to customer retail delivery
and 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: Some 2017MY SONATA HYBRID (LF HEV) and Plug-In Hybrid (LF PHEV) vehicles
may develop an abnormal noise, Hybrid/Check Engine Warning Light On and/or Engine No Start if
the pulley becomes loose at the Hybrid Starter Generator (HSG) shaft.
This bulletin provides the procedure to inspect and replace the HSG if necessary.
Applicable
Certain 2017MY Sonata Hybrid (LF HEV) and Plug-in Hybrid (LF PHEV) vehicles.
Vehicles:
Warranty Information:
Model
Op Code
70C001R1
Sonata
(LF
HEV
and
PHEV)
70C001R2
70C001R3
Operation
HSG INSPECTION
(Over 6200 miles and
inspection result OK)
HSG INSPECTION
AND REPLACEMENT
(Over 6200 miles and
inspection result NO GOOD)
HSG REPLACEMENT
(Under 6200 miles)
Op Time
Causal
Part
Nature
Code
Cause
Code
0.2 M/H
37390-2E930
Q55
ZZ1
1.7 M/H
37390-2E930
Q55
ZZ1
1.6 M/H
37390-2E930
Q55
ZZ1
NOTE 1: Submit Claim on Campaign Claim Entry Screen.
NOTE 2: If a part is found in need of replacement while performing this Service Campaign and the
affected part is still under warranty, submit a separate warranty 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.
NOTE 3: Additional coolant replacement, if necessary, is included in the labor Op Times.
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
Parts Information:
NOTE: Order the following parts only in the event of replacement of the HSG:
PART NAME
FIGURE / PART NUMBER
HSG
(HYBRID STARTER
GENERATOR)
REMARK
1 / vehicle
37390-2E930QQH
INTAKE MANIFOLD GASKET
28313-2E000
4 / vehicle
THROTTLE BODY GASKET
28312-2E000
1 / Vehicle
EGR VALVE GASKET
28314-2E900
1 / Vehicle
Special Service Tool Information:
!
IMPORTANT
You must use either of the below tools at step-18 to compress the stiffer Hydraulic
Tensioner as part of the HSG belt removal steps.
Attempting to move the Hydraulic Tensioner by wrench (as is done only for the
Mechanical Tensioner) will cause the stiffer Hydraulic Tensioner to break.
PART NAME
TENSIONER TOOL
(UNIVERSAL)
FIGURE / PART NUMBER
REMARK
NOTE: Only
order this tool if
neither tool is
found at the
dealer.
09244-G2100
NOTE: Both tools were sent to
Dealers. Either tool can work.
Do not order
this tool!
The above tool
is a
newer version.
09252-2E100
NOTE: Either tool should be available at the dealership as a required tool. If no tool can be found,
order 09244-G2100 special tool from Bosch at 1-866-539-4248.
TSB #: 17-01-045-2
Page 2 of 15
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
SUBJECT:
SERVICE PROCEDURE:
A.
Inspect vehicle odometer and proceed as indicated below based on mileage:

Over 6,200 miles:
o Perform the below Section-B. HSG INSPECTION (OP CODE : 70C001R1 or
70C001R2)

Under 6,200 miles:
o Skip to page-4 Section-C. HSG REPLACEMENT (OP CODE : 70C001R3)
B.
HSG INSPECTION:
1.
Open the hood and locate the HSG on the
passenger side of the engine compartment as
shown.
2.
Inspect the HSG pulley nut to determine
whether the paint marks line up between the
nut and bolt.
OK
NO GOOD
Based on the above nut rotation state:

OK - TSB service is complete.

NO GOOD - Proceed to the next
page Section-C. HSG REPLACEMENT
TSB #: 17-01-045-2
(OP CODE : 70C001R1)
Page 3 of 15
SUBJECT:
C.
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
HSG REPLACEMENT:
NOTE: Steps 1-4 are Important Safety Requirements to disconnect the 12V and HEV
270V Battery:
1.
Disconnect the 12V battery negative cable in the right side trunk trim.
NOTE: Prior to disconnecting, note customer’s AM/FM/XM radio presets.
2.
Remove the luggage mat and cover board to access the HEV battery.
3.
Remove the 2 safety plug cover bolts (A) and
(AA), then remove the safety plug cover (B).
A
AA
B
4.
Per HEV “General Safety Information and
Caution”, wear insulated safety gloves to
unfasten the hook (C) and remove the safety
plug (E) by pulling the lever (D) in the direction
of the arrow.
!
WARNING
Be sure to read and follow the “General
Safety Information and Caution” before
doing any work related with the high
voltage system.
Wait 5 minutes before disconnecting the
HSG connector to allow for high voltage
system capacitor discharge.
Failure to follow the safety guidelines
may result in serious electrical injuries.
TSB #: 17-01-045-2
C
D
E
Page 4 of 15
SUBJECT:
5.
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
Remove the hybrid coolant reservoir cap (F) to
help drain the coolant faster.
!
WARNING
Never remove the cap when
engine is hot. Serious scalding
could be caused by hot fluid
escaping under high pressure.
6.
F
Remove the engine room undercover. Loosen
the radiator drain plug (G) and drain the hybrid
coolant and discard.
G
7.
Disconnect the 2 cooling hoses (H) and (HH)
from the HSG.
HH
H
8.
Wearing HEV insulated safety gloves,
disconnect the orange HSG high voltage
power cable connector (I).
I
TSB #: 17-01-045-2
Page 5 of 15
SUBJECT:
9.
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
Disconnect the HSG sensor connector (J).
J
NOTE: Steps 10-16 are to remove the Intake Manifold:
10. Disconnect the wiring connectors and harness
clamps, and then remove the wiring and
protectors from the intake manifold.
11. Disconnect the positive crankcase ventilation
(PCV) hose (K) and the PCSV (purge control
solenoid valve) hose (KK).
K
KK
12. Remove the 2 bolts from the EGR cooler pipe
(L) to the intake manifold.
EGR cooler pipe bolt tightening torque:
18.6 ~ 23.5 N.m
(1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
TSB #: 17-01-045-2
L
Page 6 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
13. Disconnect the electric water pump (EWP)
hose bracket (M).
M
14. Remove the throttle body (N).
Throttle body tightening torque:
7.8 ~ 9.8 N.m
(0.8 ~ 1.0 kgf.m, 5.7 ~ 7.2 lb-ft)
N
15. Remove the intake manifold stay (O) and
connector bracket (OO).
Stay bolt tightening torque:
18.6 ~ 23.5 N.m
(1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
OO
O
Connector bracket tightening torque:
9.8 ~ 11.8 N.m
(1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
TSB #: 17-01-045-2
Page 7 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
16. Remove the intake manifold (P) with gaskets.
P
NOTICE
When reinstalling the intake manifold,
tighten the bolts and nuts with pre-torque
first. Then tighten the bolts and nuts to the
below specified torque in the sequence
shown to the right.
Intake Manifold bolt tightening torque:
18.6 ~ 23.5 N.m
(1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
NOTICE
When reinstalling the intake manifold
replace with new gaskets at the 4 intake
runners, throttle body, and EGR gaskets
listed on the page-2 Parts Information
table.
TSB #: 17-01-045-2
Page 8 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
NOTE: Steps 17-19 are for removal of the HSG belt:
17. Using a wrench, turn the mechanical tensioner
(Q) counterclockwise to compress the
tensioner and then insert stopper pin (QQ) into
the hole to hold the tensioner compressed.
Q
QQ
!
IMPORTANT
You must use the SST to compress the stiffer Hydraulic Tensioner as part of the
HSG belt removal steps.
Attempting to move the Hydraulic Tensioner by wrench (as done only for the
Mechanical Tensioner) will cause the stiffer hydraulic tensioner to break.
18. Install one of the TENSIONER SST (092522E100 or 09244-G2100 as listed on page-2) to
the hydraulic tensioner (R) and then compress
the hydraulic tensioner by tightening the
adjusting bolt (RR).
RR
NOTICE
To prevent damage to the hydraulic
tensioner, slowly tighten the SST nut by
hand. DO NOT use an impact wrench to
tighten it.
R
19. While both tensioners are compressed,
remove the drive belt (S) and inspect the belt.
NOTICE
Inspect the drive belt. Replace the belt if any
chunks are found missing from the ribs. Cracks
on rib side of the belt are OK.
TSB #: 17-01-045-2
S
Page 9 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
NOTE: Steps 20-26 are to replace HSG and assemble the intake manifold:
20. Remove the Hybrid Starter Generator (HSG)
(T) and replace with the new HSG from the
Parts Information Table.
T
HSG bolt tightening torque:
44.1 ~ 53.9 N.m
(4.5 ~ 5.5 kgf.m, 32.5 ~ 39.8 lb-ft)
20A. Prefill the new HSG with coolant from the top
tube as shown. Fill using a small funnel.
NOTE: The HSG does not need to be filled
with coolant to the top of the tube. Stop once
the HSG coolant level reaches the bottom of
the tube. Pour in slowly and carefully so as
not to overfill.
IMPORTANT
NOTICE
This step
will best ensure that air is
fully removed from the HSG.
Without this prefill step, air may not be
fully removed by the GDS bleeding
procedure. This may result in a low
hybrid coolant warning light.
21. Re-install the drive belt (S).
S
TSB #: 17-01-045-2
Page 10 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
22. Loosen the SST from the hydraulic tensioner
(R) by loosening the adjusting bolt (RR) slowly
with a hand tool. Remove the SST.
RR
R
23. Using a wrench, slightly lift the mechanical
tensioner (Q) to be able to remove the pin
(QQ). Slowly place the tensioner in position
against the belt.
Q
QQ
24. Install the Intake Manifold (P) in reverse order
of removal including new gaskets, throttle
body, EGR tube, PCV, and PCSV.
NOTE: See steps 10-16 including bolt
tightening torques.
P
25. Install the coolant hoses, high voltage connector and sensor connector to the new HSG.
26. Install the HEV 270V battery safety plug, and then the negative cable to the 12V battery.
TSB #: 17-01-045-2
Page 11 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
NOTE: Steps 27-31 are to bleed air from the Hybrid Coolant System and refill coolant:
27. Fill the reservoir with coolant and water mix at 45-50% mixture up to the MAX mark. Premix the
water and coolant to the specified ratio in a clean bucket prior to pouring it in the reservoir.
NOTICE



Use only genuine antifreeze/coolant. Do not mix brands.
For best year round corrosion protection the coolant must be mixed to
45% minimum. Greater than 55% will not provide sufficient protection
against corrosion and freezing.
Do not add rust inhibitor or antirust products; they may not be compatible
with the coolant.
28. Start the engine and allow it to come to normal engine operating temperature. Wait for the
cooling fans to come on several times. Accelerate the engine to help purge trapped air. Shut
off the engine.
29. Perform the GDS Electric Water Pump (EWP) bleeding procedure per below steps and
screenshots on the next page. Refill the hybrid coolant reservoir to between MIN and MAX
while coolant is circulating.
 From main GDS Mobile screen, select GDS “S/W Management”.
 Within “S/W Management” screen, select the “Components” tab, then choose the
“Electric Water Pump Control” option.
 With IGN ON but with READY Mode OFF (press IGN button twice without pressing the
brake pedal), select OK in the following screens to proceed.
NOTICE
If EWP operates without a sufficient amount of coolant for approximately 5
seconds, the protect function will activate to stop the EWP for about 15 seconds.
If a sufficient amount of coolant is added, EWP will start operating automatically.
TSB #: 17-01-045-2
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SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
TSB #: 17-01-045-2
Page 13 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
30. Bleeding of the hybrid coolant system is complete when the operational sound volume of the
EWP becomes small and there are no air bubbles seen in the reservoir tank. (normally takes 35 minutes).
NOTICE
After air bleeding is completed, make sure that coolant in the reservoir flows
without air bubble during EWP actuation.
If the coolant flow is not seen or air bubbles are still seen, repeat steps 27-29
again.
31. After air bleeding is completed, stop the GDS Mobile EWP bleeding function. Add coolant to
the “MAX” level, and install the reservoir cap.
NOTICE
Make sure to add more coolant than was drained initially.
Coolant Capacity:
2.2L (0.58 gal., 2.32 U.S. qt., 1.93 Imp.qt.)
32. Install the engine room undercover.
TSB #: 17-01-045-2
Page 14 of 15
SUBJECT:
HYBRID STARTER GENERATOR (HSG) INSPECTION / REPLACEMENT – SERVICE CAMPAIGN T2E
33. Restore the customer’s AM/FM/XM radio presets noted from step-1.
34. With the engine at normal operating temperature, perform GDS HSG Resolver Calibration:
35. Service Procedure Complete
TSB #: 17-01-045-2
Page 15 of 15