23-01-076H-2

GROUP
NUMBER
CAMPAIGN
DATE
Technical Service Bulletin
23-01-076H-2
MODEL(S)
December 2023
Santa Fe (CM)
CYLINDER HEAD COVER OIL LEAK REPAIR
WITH OIL PROTECTOR INSTALL AND ALTERNATOR VOLTAGE TEST
(SERVICE CAMPAIGN 976)
SUBJECT:
This TSB supersedes TSB 23-01-076H-1 with an updated Op Code (20DA06R3) and NOTE 6 under
the Warranty Information section, and a NOTE 2 under the existing part number for the generator
in the Parts Information section.
 IMPORTANT
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.
Access the “Vehicle Information” screen via WEBDCS to identify open campaigns.
Description:
Some Santa Fe (CM) vehicles may have an engine that potentially leaks oil from the front cylinder bank’s
valve cover onto the alternator. Oil could damage the alternator resulting in illumination of the charging
system warning lamp and disablement of the charging system. If the vehicle is continually driven without
recharging the battery, the engine will eventually shut off, increasing the risk of a crash. This bulletin
outlines the procedures to inspect for T-joint leakage and install an oil protector to address this issue.
 1. If the alternator voltage is less than 14.0V and there is evidence of oil leak at the T-joint,
replace the alternator, valve cover gasket, and install the oil protector.
 2. If the alternator voltage is greater than 14.0V and there is evidence of oil leak at the T-joint,
replace the valve cover gasket and install the oil protector. Do not replace the alternator.
 3. If the alternator voltage is greater than 14.0V and there is no evidence of oil leak at the T-joint,
install the oil protector. Do not replace the valve cover gasket or the alternator.
LH Cylinder
T-Joint
Applicable Vehicles (Certain):
• 2007-2009MY Santa Fe (CM) equipped with 3.3L engines and produced 04/19/2006 - 11/03/2009
Circulate To: Service Manager, Warranty Manager, Service Advisors, Technicians, Fleet Repair
SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
Parts Information:
Part Name
Part Number
QTY
Gasket - Rocker Cover LH
22453-3C120QQH
1
Service Kit – Protector, Bolts
22400-3C000QQH
1
Generator Assembly
37300-3C250QQH**
* (See below NOTE 1)
*NOTE 1: Alternator replacement is required only if alternator voltage test is less than 14.0V
and there is evidence of oil leak at the T-joint.
**NOTE 2: Part number 37300-3C250QQH may be substituted with an equivalent part number
37300-3C125QQH depending on stock availability.
Additional Materials:
Product Name
Gray Liquid RTV Gasket
Cleaning Agent
(Threebond 2706)
Part Number
Note
00232-19061
(or equivalent to TB1217H)
3 Vehicles/bottle
00232-19114
When using cleaning agents other than
recommended cleaning agents, side effects
such as reduced sealant adhesion may occur.
3 Vehicles/bottle
Warranty Information:
MODEL
Santa Fe
(CMa)
OP CODE
OPERATION
OP TIME
20DA06R0
Alternator voltage test (pass), T-joint
inspection (no oil leaks found), and oil
protector installation
1.1 M/H
20DA06R1
Alternator voltage (pass), T-joint inspection
(oil leaks found), gasket replacement & oil
protector installation
1.3 M/H
20DA06R2
Alternator voltage test (fail), T-joint inspection
(oil leaks found) & gasket replacement, oil
protector installation, & alternator
replacement (37300-3C250QQH)
2.2 M/H
20DA06R3
Alternator voltage test (fail), T-joint inspection
(oil leaks found) & gasket replacement, oil
protector installation, & alternator
replacement (37300-3C125QQH)
2.2 M/H
CAUSAL
PART
224533C120QQH
NATURE CAUSAL
CODE
CODE
E75
ZZ1
NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: If a part is found in need of replacement while performing this campaign 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.
NOTE 3: This TSB includes Repair validation photos. Op times include VIN, Mileage and Repair
validation photos as outlined in the Digital Documentation Policy.
NOTE 4: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
NOTE 5: All four op codes will reimburse the use of Threebond 2706 and Gray Liquid RTV gasket
sealant in sublet.
NOTE 6: Please ensure corresponding op code is submitted according to alternator part number
received, where applicable.
TSB #: 23-01-076H-2
Page 2 of 22
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
Service Procedure:
STUI
This TSB includes Repair validation photos. Refer to the latest Digital Documentation Policy for
requirements.
* Perform the service procedure referring to the flow chart below
Note: Icon indicates photos/video required for claim submission. Use last 6 digits of
VIN & date of repair on a piece of paper.
Vehicle Inspection
Alternator Voltage Test
Swing out alternator
Check T-Joint area for oil leak.
PASS
Clean the Oil protector assembly
NO PASS
Clean the Oil protector assembly surface.
Disassemble the Head Cover, clean and
remove sealer from the T-JOINT area.
Apply Sealant on the outside of the
head cover T-JOINT.
Clean Head Cover and replace gasket.
Install Oil Protector Assembly.
Apply Sealer to T-Joint locations and
reinstall Head Cover.
Apply sealer to the outside of Head Cover at
T-JOINT.
Install Oil Protector Assembly.
Alternator Reinstall / Replace*
* Only replace alternator if
voltage test was less than 14.0V
and T-joint inspection did not
pass.
Allow one hour for sealer to cure before starting engine.
TSB #: 23-01-076H-2
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
NOTE: In winter, the vehicle should be stored indoors to perform work on parts at room temperature.
Alternator & T-Joint Inspection
1.
Remove the engine cover (A).
A
2.
ALTERNATOR INSPECTION
Complete a voltage test of the alternator as
described below.
•
•
With the engine running at idle and the
headlamps switched on, with no other
loads switched on, measure the voltage at
B+ terminal of the alternator. In the
condition above, the alternator should
be generating 14 volts or higher.
i
Voltage Test of Alternator
Using a multimeter, connect the positive lead of the
meter to the B+ terminal (A) of the alternator.
Connect the negative lead to a ground, (not the
alternator housing). Use the test method written to
the left to determine alternator replacement.
Information
If the reading is lower than 14 volts, the
alternator may need to be replaced if the
T-joint inspection also does not pass.
TSB #: 23-01-076H-2
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SUBJECT:
SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
3.
Make note of customer radio presets and
disconnect the battery (B).
4.
Loosen the battery tray mounting fasteners
and remove the battery tray (C).
B
NOTICE
Set aside the removed battery tray (C) to
a safe area so that it does not interfere
during the alternator removal process.
5.
C
Disconnect the fan motor connectors (D).
D
D
TSB #: 23-01-076H-2
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
6.
Remove the LH fan shroud bolts (E).
Tightening torque specification:
5.0 lb-ft (60 lb-in, 6.8 Nm)
E
7.
E
Remove the LH fan shroud (F).
NOTICE
Carefully remove the LH fan shroud (F)
so that it does not damage any
surrounding parts.
F
8.
Remove the RH fan shroud bolts (G).
Tightening torque specification:
6.5 lb-ft (78 lb-in, 8.8 Nm)
G
TSB #: 23-01-076H-2
G
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
9.
Move the RH fan shroud (H) about 6 inches
towards the driver’s side of the vehicle (as
shown by the orange arrow) to provide
enough working space to remove.
6 inches
H
10. Remove the alternator upper mounting bolt
(I).
Tightening torque specification:
22 lb-ft (29.8 Nm)
11. Remove the RH wheel and tire by loosening
the 5 wheel nuts (J).
Tightening torque specification:
75 lb-ft (101.7 Nm)
J
TSB #: 23-01-076H-2
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
12. Remove the RH engine side cover (K).
K
13. Remove the undercover (L).
L
14. Disconnect the connector (M) from the A/C
compressor.
M
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15. Remove the alternator connector and the B+
terminal (N).
N
16. Remove the drive belt after relaxing the belt
tension by rotating the tensioner pivot bolt
(O).
O
17. Remove the alternator lower mounting bolt
(P).
Tightening torque specification:
22 lb-ft (29.8 Nm)
P
TSB #: 23-01-076H-2
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
18. Rotate the alternator towards the front of the
vehicle (Q).
If the alternator voltage check and t-joint
inspection both do not pass, replace the
alternator.
19. Inspect the T-Joint area for oil leak. Any oil
leakage requires the replacement of the head
cover gasket.
PASS
NO PASS
20. Take a photo of your work
STUI
Using STUI, photograph the T-joint
area. Include in the photo a piece of
paper containing the last 6 digits of
the VIN, and the date of the repair.
Ensure the photo is in focus and
captures the T-joint. Upload the photo
to STUI.
TSB #: 23-01-076H-2
Page 10 of 22
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
21. Protect the alternator or other components if
the alternator was not already removed using
a cloth or shop towel.
S
22. Remove any Pre-applied sealant and/or
contaminants using an oil and grease
removing agent. (Threebond 2706)
Remove all liquid gasket residue (including
outside area of the cylinder head and chain
cover as shown in the picture below).
NOTE
The removed liquid gasket residue should
not fall into the engine.
23. Spray the area using cleaner (Threebond
2706) and an air gun at the same time to
remove oil and foreign matter.
NOTE
Air gun pneumatic pressure: 14-28psi (1-2
bar). Cover exhaust manifold to prevent
cleaner from coming in contact.
TSB #: 23-01-076H-2
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
24. The oil protector will be sealed to the engine
at this point. It is crucial that this area is free
from oil and contaminates.
- (T) Area : Head, Head Cover, Chain Cover,
and Block.
i
Information
After cleaning the T-joint of the head
cover, scrub with a clean cloth and clean
it with a Threebond 2706 if the oil sludge
remains between the chain cover and
gap in the head.
i
Information
If any oil sludge remains even after
washing with the Threebond 2706,
remove with a brush. Use a
mirror/magnifying glass to check the oil
sludge removal.
25. Take a photo of your work.
STUI
Using STUI, photograph the T-joint
area. Include in the photo a piece of
paper containing the last 6 digits of
the VIN, and the date of the repair.
Ensure the photo is in focus and
captures the T-joint. Upload the
photo to STUI.
TSB #: 23-01-076H-2
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
26. If no leak was found at T-Joint area on step
19, do not remove head cover and skip steps
27 thru 40 and go to step 41.
B
27. Remove the upper mounting bracket bolt (B)
near the OCV connector.
28. Remove the lower mounting bracket bolt (C)
near the B2S1 oxygen sensor connector.
C
29. Disconnect the bank 2 ignition coil
connectors (D), and remove the ground (E),
and then remove the wiring harness protector
(F).
F
G
30. Disconnect the bank 2 Camshaft Position
Sensor (CMPS) at (G).
E
D
31. Remove the hose (H) and disconnect
harness connectors (I) from the bank 2 fuel
injectors.
I
D
D
I
I
H
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32. Unlock the terminal cable clips (J).
33. Remove alternator “B” terminal cable
mounting bracket bolts (K) and then remove
the wire bracket bolts (L).
J
J
L
K
34. Remove the bank 2 ignition coils (M).
M
M
M
35. Remove the bank 2 (LH) cylinder head cover
(N).
Tightening torque specification:
8.0 lb-ft (96 lb-in, 10.8 Nm)
N
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
NOTICE
Carefully remove the cylinder head cover to avoid any dirt/debris falling into
the engine. Debris falling into the cylinder head can result in engine damage.
36. Remove all remaining liquid gasket residue
(including outside area of the cylinder head
and chain cover as shown in the picture
below).
NOTICE
•
•
Be careful not to damage the surface of
the cylinder head cover.
The removed liquid gasket residue
should not fall into the engine.
37. Clean the cylinder head and cover with a
clean lint-free shop towel referring to the
picture of the cleaning area below
(highlighted in red).
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
38. With Threebond 2706, clean off any of the
remaining dirt and oil from the cylinder head
and cover and then wipe dry with a clean lintfree shop towel.
O
39. Remove the cylinder head cover gasket (P).
P
40. Install the new cylinder head cover gasket
(Q).
NOTICE
Before installing the new gasket (Q),
clean the gasket installing groove with a
Threebond 2706 and a clean lint-free
shop towel.
Q
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41. Apply liquid RTV gasket (00232-19061) onto
the “T” joints (R), which are the mating points
where the front timing chain cover and the
cylinder head meet.
R
NOTICE
When applying the liquid RTV gasket,
the applied bead on the surface should
be approximately 3/16th in (4.5 mm)
wide as shown in the picture below.
3/16th in
(4.5 mm)
Carefully reinstall the cylinder head cover
within the next several minutes before the
liquid RTV gasket begins to harden.
Tightening torque specification:
8.0 lb-ft (96 lb-in, 10.8 Nm)
NOTICE
When reinstalling the cylinder head
cover, tighten the bolts in the order as
shown in the picture at right.
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42. Remove (two) chain cover bolts shown here
(K).
i
Information
When removing the two chain cover bolts
it is possible for retained oil to come out.
If oil escapes through bolt holes, clean
thoroughly with Threebond 2706.
43. Apply liquid RTV gasket onto the outer
surface of the “T” joints (S) of the cylinder
head and cover.
• Apply the liquid RTV gasket in a line at
least 30 mm long, following the green bold
line as shown in the picture on the right
and below.
S
Application area (Φ 4.5)
30 mm
•
Within several minutes before the liquid
RTV gasket begins to harden, spread the
gasket evenly as shown in the picture on
the right.
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i
Information
If sealant is applied after using
cleaning agent, apply sealant after the
surface is dried.
When sealant is applied to the T-Joint,
apply it to the head cover.
If it is difficult to visually check the
correct position due to the narrow
space in the engine room when
applying the sealant, use a mirror to
check the sealant position and
proceed with the operation.
44. Apply sealant onto the oil protector at the
indicated areas pictured (OO, PP, QQ).
Note:
Be careful not to block the exit. If sealant
falls into the inside of the bottom of the oil
protector, thoroughly remove sealant and
reapply. (To prevent clogging of the oil
drain passage)
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45. Apply Sealant onto (MM) and (NN) area as
shown in the photo.
46. Take a photo of your work.
STUI
Using STUI, photograph the T-joint
area. Include in the photo a piece of
paper containing the last 6 digits of
the VIN, and the date of the repair.
Ensure the photo is in focus and
captures the T-joint. Upload the photo
to STUI.
TSB #: 23-01-076H-2
Page 20 of 22
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SUBJECT: CYLINDER HEAD COVER OIL LEAK REPAIR (SERVICE CAMPAIGN 976)
47. Place oil protector in place.
1.) Install oil protector to the timing chain
cover in the indicated angle pictured
in (RR).
2.) Be careful not to contact surrounding
parts.
Note:
If the sealant is heavily smeared on the
surrounding parts, remove the oil
protector, thoroughly clean the sealant
from surrounding areas and clean the oil
protector. Go back to 41 and repeat.
48. Install provided kit bolts into the oil protector.
-Replace with service kit bolts and arrange
the oil protector in the correct position by
temporarily fastening to chain cover.
• Bottom bolt (provided): 2512432C500QQH (M8X35mm)
• Upper bolt (provided): 11403-08456K
(M8X45mm)
- Check fitment of the oil protector.
- Firmly press sealing surface by hand.
- Keep it in loose contact with the engine.
Tightening Torque:
15.0 lb-ft (20Nm)
Note:
Do not use original chain cover bolts.
49. Remove sealant from the alternator mount
(SS).
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50. Apply the sealant to the (TT) area to seal the
oil protector to block.
51. Reinstall all removed parts in reverse order of
removal.
Refer to Shop Manual:
Engine Mechanical System > Charging
System > Alternator > Repair procedures
Only replace alternator if voltage test was
less than 14.0V and T-joint inspection did not
pass.
NOTICE
• Allow at least one hour for the liquid RTV gasket to cure before starting the engine.
• Reprogram the radio presets recorded from Service Procedure Step 4.
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SUBJECT: