23-EE-006H

GROUP
NUMBER
ENGINE ELECTRICAL
DATE
Technical Service Bulletin
23-EE-006H
MODEL(S)
APRIL 2023
SONATA (DN8)
JE202 JOINT CONNECTOR REPAIR
(P049D,P0405,P0489,P0191,P0507 AND/OR P240F)
SUBJECT:
Description: This bulletin provides the procedure to repair poor pin tension at joint connector JE202 in
certain Sonata (2.5L GDI engine) with one or more DTC.
Applicable Vehicles:
• All 2020-2023MY Sonata (DN8) equipped with 2.5L GDI Engine (VINs starting with 5NP)
Parts Information:
MODEL
PART NAME
Haisstronica Marine Grade Solder
and Seal Connectors AWG 16-14
Locally obtained
PHOTO
QTY
3
Warranty Information:
MODEL
OP CODE
OPERATION
Sonata
(DN8)
91201FJ2
Repair JE202
OP TIME CAUSAL PART
0.9 M/H
91410-L0063
NATURE
CODE
CAUSAL
CODE
I3T
ZZ3
NOTE 1: Normal Warranty applies.
NOTE 2: Include cost of AWG 16-14 in sublet as part of claim submission for reimbursement.
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
JE202 JOINT CONNECTOR REPAIR
Service Procedure:
1. Remove Engine Cover.
2. Disconnect Negative Battery Terminal and
make note of customer radio presets to
program back later.
 NOTE
Tightening Torque
6.5 lb-ft
3. Disconnect both PCM Connectors.
TSB #: 23-EE-006H
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SUBJECT:
SUBJECT:
JE202 JOINT CONNECTOR REPAIR
4. Unclip Joint Connector JE202 from the Control
Harness.
 Trim the tape on the harness to allow for
more wire.
 Cut all wires going to JE202 as close to the
Connector Body as possible as shown.
(Discard the JE202 after wire cutting.)
 Strip 3/8” of the insulation from all wires.
5. Using Solder and Seal Connectors, twist,
install and splice circuits as stated below and
shown on the right. Using a Micro Torch or
Heat Gun, melt the solder in the connector
and seal. Refer to Online ETM if additional
information is required.
 Connect all Red, Red/black wires
together.
 Connect all Orange, Orange/Black wires
together.
 Connect all White, White/Black wires
together.
NOTE: Depending on vehicle options, there
may be a different number if wires on JE202
that need to be spliced. Refer to online ETM if
additional information is required.
CAUTION
Use caution when heating the
connectors to prevent damage
to the fuel line.
6. Using a Zip Tie, secure the repaired wiring to
the Control Harness.
7. Reassemble in reverse order of disassembly.
8. Clear DTC’s and Reset Adaptive Values.
TSB #: 23-EE-006H
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SUBJECT: