20-01-003H

GROUP
CAMPAIGN
DATE
Technical Service Bulletin
SUBJECT:
January, 2020
NUMBER
20-01-003H
MODEL(S)
2016-2017MY
SONATA HYBRID
2016-2017MY SONATA HEV MAIN RELAY / POWER RELAY
ASSEMBLY / HIGH VOLTAGE CABLE ASSEMBLY REPLACEMENT
(SERVICE CAMPAIGN T4M)
 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: 2016 – 2017 model year Sonata LF HEV vehicles contain a Power Relay
Assembly (“PRA”). The PRA is equipped with a main relay and High Voltage Cable, which in
some instances may have a loose connection. If the vehicle continues to operate in this
condition, a loose connection could cause a no start condition or a Check Engine and Hybrid
Warning Light On with either or both of these DTCs stored:
 DTC P1B77 – High Voltage Battery Precharging Fault
 DTC P1990 – Oil Pump Unit Input High Voltage Wiring Line Open
This bulletin describes the procedure to inspect the PRA, High Voltage Cable, and main relays
and replace them if necessary.
Applicable Vehicles: Certain 2016-2017MY Sonata Hybrid (LF HEV) vehicles
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT: 2016 -2017MY SONATA HYBRID MAIN RELAY / PRA / HIGH VOLTAGE CABLE REPLACEMENT (SERVICE CAMPAIGN T4M)
Parts Information:
Part Name
Part Number / Figure
Qty
MAIN RELAY
Note
Only required
based on vehicle
inspection results.
Refer to Service
Procedure.
1
Note: The main
relays are
packaged as a set
of two.
Includes new main
relays preinstalled.
37583-A8000QQH
POWER RELAY
ASSEMBLY
Only required
based on vehicle
inspection results.
Refer to Service
Procedure.
1
37514-G0000QQH
Only required
based on vehicle
inspection results.
Refer to Service
Procedure.
HIGH VOLTAGE CABLE
1
91875-E6000QQH
Warranty Information:
Model
Sonata Hybrid
(LF HEV)
Op Code
Operation
Op
Time
Causal
Part
90C058R0
PRA INSPECTION AND
MAIN RELAY REPLACEMENT
0.6 M/H
37583A8000
90C058R1
PRA INSPECTION AND
PRA REPLACEMENT
0.6 M/H
37514G0000
90C058R2
PRA INSPECTION AND PRA
AND HIGH VOLTAGE CABLE
REPLACEMENT
3.2 M/H
91875E6010
Nature
Code
Cause
Code
I3A
ZZ3
IMPORTANT:
NOTE 1: Submit Claim on Campaign Claim Entry Screen.
NOTE 2: If a part is found in need of replacement while performing Service Campaign T4M 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 the repair.
TSB #: 20-01-003H
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SUBJECT:
SUBJECT:
2016 -2017MY SONATA HYBRID MAIN RELAY / PRA / HIGH VOLTAGE CABLE REPLACEMENT (SERVICE CAMPAIGN T4M)
!
DANGER
The vehicle contains a high voltage battery and associated components. Follow
all applicable electrical system precautions outlined in the Shop Manual before
performing the procedure.
Shop Manual > General Information > General Safety Information and Caution
Service Procedure:
1.
Follow the High Voltage Shut-off
Procedure in the Shop Manual before
performing any work.
Shop Manual > General Information >
High Voltage Shut-off Procedure
!
WARNING
Follow the high voltage Shut-off procedure before performing the inspection
or any repairs.
2.
The Power Relay Assembly (“PRA”)
and main relays will be inspected.
Remove the PRA assembly according
to the Shop Manual.
Hybrid control system > High Voltage
Battery System > Power Relay
Assembly (PRA)
TSB #: 20-01-003H
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SUBJECT: 2016 -2017MY SONATA HYBRID MAIN RELAY / PRA / HIGH VOLTAGE CABLE REPLACEMENT (SERVICE CAMPAIGN T4M)
3.
Spread the main relay hooks at the top
and bottom of the relay using a flat
head screwdriver.
4.
Insert screwdrivers between the PRA
housing and main relay to hold and
disengage the top and bottom hooks.
5.
With the screwdrivers inserted remove
the main relays with Oil Filter Pliers,
Water Pump Pliers, or a similar tool.
TSB #: 20-01-003H
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SUBJECT:
6.
2016 -2017MY SONATA HYBRID MAIN RELAY / PRA / HIGH VOLTAGE CABLE REPLACEMENT (SERVICE CAMPAIGN T4M)
Inspect the PRA and main relays.
If either the PRA OR main relays are
damaged: Replace the PRA according to
the Shop Manual. The new PRA comes
with new main relays preinstalled. Use
Labor Op Code: 90C058R1
Hybrid Control System > High Voltage
Battery System > Power Relay Assembly
(PRA)
NOTICE
The specific location(s) and extent
of damage can vary. If any damage
is present, replace the PRA.
DAMAGED
If the PRA AND main relays are NOT
damaged: Proceed to step 7.
NO
DAMAGE
TSB #: 20-01-003H
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SUBJECT: 2016 -2017MY SONATA HYBRID MAIN RELAY / PRA / HIGH VOLTAGE CABLE REPLACEMENT (SERVICE CAMPAIGN T4M)
7.
Inspect the PRA Inverter Power
Terminals and High Voltage Cable
connectors.
If either the terminals or connectors are
damaged, replace the High Voltage
Cable and the PRA if it was not
replaced in step 6. Use Labor Op
Code: 90C058R2
Shop Manual:
Hybrid Control System > Power Cable
NOTICE
The specific location(s) and extent
of damage can vary. If any damage
is present, replace the High
Voltage Cable and the PRA.
If the PRA, the High Voltage Cable
connectors, and main relays are NOT
damaged: Replace both main relays
according to the Shop Manual. Use
Labor Op Code: 90C058R0
Hybrid Control System > High Voltage
Battery Control System > Main Relay
8.
Reinstall all removed parts in the
reverse order of removal.
Check for DTCs and perform the
appropriate diagnostic service. Ensure
no warning lights are present.
TSB #: 20-01-003H
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