22-ST-001H

GROUP
STEERING
DATE
Technical Service Bulletin
SUBJECT:
JANUARY, 2022
NUMBER
22-ST-001H
MODEL(S)
Sonata (LFa)
Sonata Hybrid (LF HEV)
Sonata Plug-In Hybrid (LF
PHEV)
2015-2017MY SONATA (LFA) AND SONATA HYBRID/PLUG-IN
HYBRID (LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Description: The warranty coverage for certain 2015-2017MY Sonata (LFa) and Sonata HEV/PHEV (LF
HEV/PHEV) vehicles exhibiting reduced power steering assist and/or motor driven power steering
(MDPS) warning lamp has been extended to 15 years or 150,000 miles from the date of original retail
delivery or date of first use, whichever occurs first. Refer to the warranty, service parts information, and
diagnostic information outlined in this bulletin.
Applicable Vehicles:
• Certain 2015-2017MY Sonata (LFa) vehicles produced from January 30, 2014 to June 19, 2017.
• Certain 2015-2017MY Sonata HEV/PHEV (LF HEV/PHEV) vehicles produced from September
17, 2014 to December 27, 2017.
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Parts Information:
Models
Image
Part Information
Torque sensor cable:
56397-C1100FFF
C-MDPS ECU:
56340-C2500 (LFa)
56340-E6500 (LF (P)HEV)
C-MDPS Motor:
56330-C1500
Sonata (LFa) 2.4L and Sonata
HEV/PHEV (LF HEV/PHEV)
vehicles equipped with columnmounted MDPS (C-MDPS)
Steering Column & Housing
Assembly:
56390-C1500 (NONSMART KEY TYPE)
NOTE: Not applicable to
Sonata Hybrid / Plug-In
models
56390-C1700 (SMART KEY
TYPE)
Short gear assembly:
57770-C2000 (15MY)
57770-C2050 (16, 17MY)
Power pack:
Sonata (LFa) 2.0T vehicles
equipped with rack-mounted
MDPS (R-MDPS)
56320-C2000 (15MY)
56320-C2050 (16, 17MY)
TSB #: 22-ST-001H
Page 2 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Warranty Information:
Models
Op. Code
Operation
10D119R0
C-MDPS DIAGNOSTIC
INSPECTION
0.3 M/H
56340C2500
10D119R1
C-MDPS DIAGNOSIS
INSPECTION AND
TORQUE SENSOR CABLE
REPLACEMENT
0.5 M/H
56397C1100
FFF
1.9 M/H
56390C1500
1.7 M/H
56390C1700
10D119R4
C-MDPS DIAGNOSTIC
INSPECTION AND
C-MDPS ECU REPLACEMENT
1.1 M/H
56340C2500
10D119R5
C-MDPS DIAGNOSTIC
INSPECTION AND
C-MDPS MOTOR REPLACEMENT
1.2 M/H
56330C1500
10D119R6
C-MDPS DIAGNOSTIC
INSPECTION
0.3 M/H
56340E6500
10D119R7
C-MDPS DIAGNOSIS
INSPECTION AND
TORQUE SENSOR CABLE
REPLACEMENT
0.5 M/H
56397C1100
FFF
1.7 M/H
56397C1700
1.1 M/H
56340E6500
1.2 M/H
56330C1500
C-MDPS DIAGNOSIS INSPECTION,
TORQUE SENSOR CABLE
Sonata (LFa) 10D119R2 REPLACEMENT AND COLUMN &
HOUSING REPLACEMENT (NON2.4L vehicles
SMART KEY TYPE)
equipped with
columnC-MDPS DIAGNOSIS INSPECTION,
mounted MDPS
TORQUE SENSOR CABLE
(C-MDPS)
10D119R3 REPLACEMENT AND COLUMN &
HOUSING REPLACEMENT (SMART
KEY TYPE)
Sonata Hybrid /
C-MDPS DIAGNOSIS INSPECTION,
Plug-In (LF
TORQUE SENSOR CABLE
HEV / PHEV)
10D119R8
REPLACEMENT
AND COLUMN &
equipped with
HOUSING REPLACEMENT (SMART
columnKEY TYPE)
mounted MDPS
(C-MDPS)
C-MDPS DIAGNOSTIC
10D119R9
INSPECTION AND
C-MDPS ECU REPLACEMENT
C-MDPS DIAGNOSTIC
10D119RA
INSPECTION AND
C-MDPS MOTOR REPLACEMENT
TSB #: 22-ST-001H
Op. Time Causal Nature Cause
I3A
ZZ3
Page 3 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Models
Op. Code
Operation
10D119RB
R-MDPS DIAGNOSTIC
INSPECTION
Op. Time Causal Nature Cause
R-MDPS DIAGNOSTIC
Sonata (LFa)
INSPECTION, STEERING SHORT
2.0T vehicles 10D119RD
GEAR ASSEMBLY REPLACEMENT,
equipped with
AND TOE-IN ADJUST
rack-mounted
MDPS (RR-MDPS DIAGNOSTIC
MDPS)
INSPECTION,
10D119RE
STEERING POWER PACK
REPLACEMENT, AND TOE-IN
ADJUST
0.3 M/H
57770C2050
1.9 M/H
57770C2050
I3A
1.9 M/H
ZZ3
56320C2050
NOTE 1: Submit Claim on Campaign Claim Entry Screen
NOTE 2: If a part that is not covered by this warranty extension is found in need of replacement while
performing Warranty Extension TXXO 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.
Service Procedure: Overview
NOTICE
•
Perform the C-MDPS diagnostic inspection using the GDS/GDS-M.
•
Always refer to the applicable model shop manual for detailed information regarding the
failure code diagnosis and component replacement procedures.
•
Note that some codes may be found in systems other than EPS (electric power steering)
in GDS. They may be found in the Brake/ABS/ESC system. Check all systems for the failure
codes.
•
Reduced power steering assist concerns should have current or historical DTCs stored.
If no DTCs are detected, refer to the applicable shop manual section or contact Techline for
further assistance.
TSB #: 22-ST-001H
Page 4 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
C-MDPS Diagnostic Trouble Code (DTC) Repair Flowchart:
Warning Lamp Illuminated – DTC(s)
present / CAN Line Error
1. Check C-MDPS connectors and wiring.
2. Erase DTC(s) and re-check.
 If C1259 or C1290 is found in history OR active,
replace the torque sensor cable.
3. If DTC(s) still present, follow these recommended repairs.
ECU Related
C1112
C1604
C1623
C1687
C1704
C1705
C2412
C2413
Replace the
C-MDPS
ECU.
Motor
Related
C2400
C2401
Torque Sensor
Cable Related
C1259
C1290
Other
C1102
C1603
C1102 – Inspect
12V charging
system & battery
Replace
the
CMDPS
motor.
Replace torque
sensor cable first.
If DTCs persist,
then replace the
column &
housing assy.
C1603 –
Thermal protection.
Wait 20-30
seconds for the
system to cool
down.
TSB #: 22-ST-001H
Connectors / Wiring Related
C1260, C1261, C1611, C1612, C1616,
C1622, C1628, C1646, C1656, C1692,
C1693, C1696, C1697, C1688
Check DTC(s) and Wiring at
HECU / C-MDPS / EMS
• Check connectors for poor
connection.
• Check for connector corrosion.
• Check for connector damage or
deformation.
• Check the DTC Diagnostic
Guide on HyundaiTechInfo.com
Page 5 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
R-MDPS Diagnostic Trouble Code (DTC) Repair Flowchart:
Warning Lamp Illuminated – DTC(s)
present / CAN Line Error
1. Check R-MDPS connectors and
wiring.
2. Erase DTC(s) and re-check.
3. If DTC(s) still present, follow these
recommended repairs.
Power-Pack Related
C1687
C1112
C1604
C1700
C1704
C1705
C2401
C2412
C2413
Replace the
Power Pack assembly.
Short-Gear
Related
C1290
Other
C1102
C1603
C1102 – Inspect
12V charging
system & battery
Replace
short-gear
assembly.
C1603 –
Thermal protection.
Wait 20-30 seconds
for the system to
cool down.
TSB #: 22-ST-001H
Connectors / Wiring Related
C1611, C1613, C1616, C1622, C1633,
C1628, C1659, C1692, C1693, C1696,
C1697, C1804, C1805, C1812, C1814,
C1817, C166B, C1202, C1211, C16B2,
C16BF
•
•
•
•
Check DTC(s) and Wiring at
HECU / R-MDPS / EMS
Check connectors for poor
connection.
Check for connector corrosion.
Check for connector damage or
deformation.
Check the DTC Diagnostic
Guide on HyundaiTechInfo.com
Page 6 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Service Procedure: C-MDPS/R-MDPS Diagnostic Inspection
1.
Locate the OBD2 port on the driver’s
side dash panel. Connect GDS to
vehicle via VCI.
2.
Select the vehicle type, then check all
systems for diagnostic trouble codes
(DTCs).
3.
If any DTCs are found, follow the
procedures described in the warning
lamp repair flowcharts above.
If no DTCs are found, no further repair
is required and the service procedure is
complete.
TSB #: 22-ST-001H
Page 7 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Service Procedure: Torque Sensor Cable Replacement
1.
If applicable, record the customer’s
radio presets and turn the ignition
switch OFF.
Disconnect the negative (-) 12V battery
terminal and wait at least 30 seconds.
Open the driver’s front door and pull
back the weather stripping.
2.
Remove the dash side cover.
TSB #: 22-ST-001H
Page 8 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
3.
Remove the 2 screws.
4.
Remove the cover to access the bolt on
the lower dash. Remove the bolt.
5.
Unfasten the retaining hook on the side
of the dash.
TSB #: 22-ST-001H
Page 9 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
6.
Remove the lower cover assembly and
disconnect the associated wiring
harnesses.
7.
Remove the mounting bolts for the
driver’s knee air bag.
Tightening Torque:
8 ~ 12 N.m. (0.8 ~ 1.2 kgf.m, 5.9 ~ 8.8
Ibf-ft)
TSB #: 22-ST-001H
Page 10 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
8.
Disconnect the knee air bag connector
and remove the air bag assembly.
9.
Remove the cable protection cover on
the torque sensor cable and disconnect
the connector.
TSB #: 22-ST-001H
Page 11 of 21
SUBJECT:
SUBJECT:
10.
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Remove the ECU side connector
double lock and connector using the flat
screwdriver.
TSB #: 22-ST-001H
Page 12 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
11.
Remove the torque sensor cable fixing
clip using the long-nose pliers.
12.
Remove the torque sensor cable and
replace it with a new one.
NOTICE
1. Install in reverse order of
removal.
2. Conduct self-diagnosis after
installation.
3. If the diagnosis is normal,
finish the operation.
4. If there is a problem after
replacing the cable, replace
column & housing.
5. Restore the customer’s radio
presets.
Service Procedure: C-MDPS Column & Housing Replacement
1.
If applicable, record the customer’s
radio presets and turn the ignition
switch OFF.
Disconnect the negative (-) 12V battery
terminal and wait at least 30 seconds.
Remove the MDPS assembly per
appropriate service manual procedures.
TSB #: 22-ST-001H
Page 13 of 21
SUBJECT:
SUBJECT:
2.
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Remove the C-MDPS motor mounting
screws.
Tightening Torque:
8 ~ 12 N.m. (0.8 ~ 1.2 kgf.m, 5.9 ~ 8.8
Ibf-ft)
TSB #: 22-ST-001H
Page 14 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
3.
Remove the MDPS ECU connector.
4.
Remove the MDPS motor assembly.
5.
Remove the MDPS ECU mounting
bolts.
Tightening Torque:
20 ~ 24 N.m. (2 ~ 2.5 kgf.m, 14.8 ~
17.7 Ibf-ft)
TSB #: 22-ST-001H
Page 15 of 21
SUBJECT:
SUBJECT:
6.
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Remove the MDPS ECU mounting
screws.
Tightening Torque:
8 ~ 10 N.m. (0.8 ~ 1 kgf.m, 5.9 ~ 7.4
Ibf-ft)
7.
Remove the MDPS ECU.
8.
Remove the MDPS rubber coupling.
TSB #: 22-ST-001H
Page 16 of 21
SUBJECT:
SUBJECT:
9.
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Install the removed MDPS ECU, motor,
and coupling to the new column &
housing assembly.
Install the MDPS assembly into the
vehicle in reverse order of removal.
Service Procedure: C-MDPS ECU Replacement
1.
If applicable, record the customer’s
radio presets and turn the ignition
switch OFF.
Disconnect the negative (-) 12V battery
terminal and wait at least 30 seconds.
Remove the MDPS assembly per
appropriate service manual procedures.
2.
Remove the MDPS ECU connector.
TSB #: 22-ST-001H
Page 17 of 21
SUBJECT:
SUBJECT:
3.
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Remove the MDPS ECU mounting
bolts.
Tightening Torque:
20 ~ 24 N.m. (2 ~ 2.5 kgf.m, 14.8 ~
17.7 Ibf-ft)
4.
Remove the MDPS ECU mounting
screws.
Tightening Torque:
8 ~ 10 N.m. (0.8 ~ 1 kgf.m, 5.9 ~ 7.4
Ibf-ft)
5.
Remove the MDPS ECU.
Install the new MDPS ECU in reverse
order of removal.
Restore the customer’s radio presets.
TSB #: 22-ST-001H
Page 18 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Service Procedure: C-MDPS Motor Replacement
1.
If applicable, record the customer’s
radio presets and turn the ignition
switch OFF.
Disconnect the negative (-) 12V battery
terminal and wait at least 30 seconds.
Remove the MDPS assembly per
appropriate service manual procedures.
2.
Remove the C-MDPS motor mounting
screws.
Tightening Torque:
8 ~ 12 N.m. (0.8 ~ 1.2 kgf.m, 5.9 ~ 8.8
Ibf-ft)
TSB #: 22-ST-001H
Page 19 of 21
SUBJECT:
SUBJECT:
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
3.
Remove the motor from the assembly.
4.
Disconnect the power connector.
TSB #: 22-ST-001H
Page 20 of 21
SUBJECT:
SUBJECT:
5.
2015-2017MY SONATA (LFA, LF HEV/PHEV) MDPS (WARRANTY EXTENSION TXXO)
Remove the motor assembly.
Install the new motor assembly in
reverse order of removal.
Restore the customer’s radio presets.
Service Procedure: R-MDPS Power Pack Replacement and Short Gear Assembly Replacement
NOTICE
For service procedures on R-MDPS LFa Sonata vehicles, refer to TSB #21-ST-001H and
the applicable Service Manual.
TSB #: 22-ST-001H
Page 21 of 21
SUBJECT: