Engine - Titanium O2 Sensors
SOURCE: Hyundai Tech Net Times Volume 14 Issue 2 2004TITLE: Engine - Titanium O2 Sensors
APPLIES TO: 2.5/2.7L V-6 Sonata and Santa Fe
SERVICE TIP:
DESCRIPTION:
^ This article supersedes TSB# 03-01-011-1 and 03-01-011.
^ PLEASE READ ENTIRE ARTICLE BEFORE STARTING REPAIR PROCEDURE. FIRST STEP CHECK THE "WARRANTY VEHICLE INFORMATION" SCREEN PRIOR TO ANY REPAIR BEING PERFORMED TO IDENTIFY THE APPROPRIATE REPAIR REQUIRED FOR EACH VEHICLE: SERVICE PROCEDURE:
1. When a vehicle arrives at the Service Department, access Hyundai Motor America's "Warranty Vehicle Information" screen via DCS Interactive or DCS On-Line to identify open campaigns.
2. The screen will provide the applicable labor operation/ repair to be performed on each vehicle with an incompleted "V01" campaign. Only the repair identified must be performed.
3. The "Warranty Vehicle Information" screen will identify each of the affected V01 Campaign vehicles with one of the following four possible descriptions.
V01 31B043R1 SENSOR-REPL BOTH SIDES &
REPRG 0301011-02
* Note: Requires replacement of "BANK 1 and 2"
V01 31B043R2 SENSOR-REPL "RH" SIDE & REPRG 0301011-02
* Note: Requires replacement of "BANK 1"
V01 31B043R3 SENSOR-REPROGRAM ONLY 0301011-02
* Note: No replacement is necessary
V01 31B043R4 SENSOR-REPL "LH" SIDE & REPRG 0301011-02
* Note: Requires replacement of "BANK 2"
* Italics do not appear on DCS interactive/on-line screens
NOTE: Only the repair identified on the Warranty Vehicle Information screen associated with that vehicle should be performed by the technician.
For example: For Campaign V01, the following vehicle has been identified as needing only the "RH" side oxygen sensor to be replaced and the ECM to be reprogrammed. There is no requirement to replace the "LH" side oxygen sensor. Therefore, in this example, the LH oxygen sensor would not be replaced.
IMPORTANT:
"RH" side is the Dash Panel Side of the Engine (also called "BANK 1").
"LH" side is the Radiator Side of the Engine (also called "BANK 2").
CONDITION DESCRIPTION:
Some 1999 2001 MY Sonata and Santa Fe vehicles equipped with 2.5/2.7L V6 engines and Titanium O2 Sensors may experience the following conditions:
"Check Engine" light on.
One or more of the following Diagnostic Trouble Codes (DTC) stored in the ECM:
B1/S1: Bank 1 (RH, Dash panel side)/Sensor 1 (Before Catalyst)
^ P0133: Front O2 circuit slow response bank 1.
^ P0134: Front O2 circuit inactive bank 1.
^ P1134: Transition time problem O2 sensor bank 1 sensor 1.
B2/S1: Bank 2 (LH, Radiator side)/Sensor 1 (Before Catalyst)
^ P0153: Front O2 circuit slow response bank 2.
^ P0154: Front O2 circuit inactive bank 2.
^ P1154: Transition time problem O2 sensor bank 2 sensor 1.
REPAIR PROCEDURE:
1. Determine which repair is needed by using the "Warranty Vehicle Information" screen via DCS.
2. Replace the appropriate O2 sensor per the "Warranty Vehicle Information" screen.
NOTE: Some vehicles will NOT require the replacement of any O2 sensors.
3. Reprogram the ECM.
4. Make the appropriate warranty claim using the appropriate Op Code.
VEHICLES AFFECTED:
ECM SPECIFICATION TABLES:
SANTA FE:
SONATA:
1999-2001 SONATA V6O2 SENSOR REPLACEMENT PROCEDURE:
Bank 1 (Dash Panel Side) Front O2 Sensor:
1. Disconnect the B1/S1 O2 sensor connector from the top.
2. Lift the vehicle and remove the front pipe assembly (as shown in the picture) to access the upstream O2 sensor.
3. Replace the B1/S1 O2 sensor with the improved part (39210-3712A). Use a 22mm O2 sensor socket.
4. Torque the new O2 sensor to 33 lb-ft.
5. Reinstall the front pipe assembly.
6. Lower the car and reconnect the O2 sensor connector.
Bank 2 (Radiator Side) Front O2 Sensor:
1. Disconnect the condenser fan and remove the assembly (remove two 10mm socket bolts at the top of the assembly) to access the Bank 2 Front O2 sensor.
2. Replace the B2/S1 O2 sensor with the improved part (39210-3716A). Use a 22mm O2 sensor socket.
3. Torque the new O2 sensor to 33 lb-ft.
4. Reinstall the condenser fan assembly and reconnect the electrical connector.
2001 SANTA FE V6O2 SENSOR REPLACEMENT PROCEDURE: Bank 2 (Radiator Side) Front O2 Sensor:
1. Disconnect the B2/S1 O2 sensor connector.
2. Replace the B2/S1 O2 sensor with the improved part (39210-3716A). Use a 22mm O2 sensor socket.
3. Torque the new O2 sensor to 33 lb-ft.
Bank 1 (Dash Panel Side) Front O2 Sensor:
1. Disconnect the B1/S1 O2 connector from the top of the vehicle.
2. Lift the vehicle.
3. Replace the B1/S1 O2 sensor with the improved part (39210-3712A). Use a 22mm crows-foot type of O2 sensor socket.
4. Torque the new O2 sensor to 33 lb-ft.
NOTE: The 4WD version of the Santa Fe is shown in these pictures.
5. To torque the B1/S1 O2 sensor, a specific setup of torque wrench, extension and socket is required (as shown in the picture below).
6. Lower the vehicle and connect the new O2 sensor.
REPROGRAMMING PROCEDURE:
The following procedure describes the Reprogramming Procedure for the Sonata.
The procedure for the Santa Fe is not shown in detail, but is the same. All required ECM information and Manual Method Password information are included on page 4 of this TSB for both the Sonata and Santa Fe.
CAUTIONS BEFORE REPROGRAMMING:
1. Conduct reprogramming with the ignition key in the "ON" position.
2. Be careful not to disconnect any cables connected to the vehicle or Hi-Scan Pro during reprogramming.
WARNING: If reprogramming is interrupted, the manual update procedure must be used.
3. Do not start the engine during reprogramming.
4. Do not turn the ignition key off during reprogramming.
5. Clear all diagnostic codes related to the upstream O2 sensors on bank 1 and bank 2 before conducting ECM reprogramming. Then, cycle the ignition key ON and OFF three times (each time, waiting 10 seconds before turning the key back on) before proceeding with the reprogramming.
AUTOMATIC UPDATE PROCEDURE:
1. Attach the DLC (Data Link Connector) cable to the Hi- Scan Pro main body and tighten the 2 bolts securely.
2. Remove any software cards from the Hi-Scan Pro and insert the new reprogramming card into the Hi- Scan Pro's top slot.
3. Plug the DLC cable from the Hi-Scan Pro into the data link connector (16-pin connector) at the driver's side lower crash pad.
4. Turn the ignition to the ON position.
5. Turn the Hi-Scan Pro ON and press ENTER.
6. Select option "32. EF 2.5 & 2.7 TiO2S HEATING IMPROVEMENT" and press ENTER. For Santa Fe, select option "33. SM 2.7 TiO2S HEATING IMPROVEMENT" and press ENTER.
7. Select "01. EF 2.5 & 2.7 TiO2S HEATING [AUTO]" and press ENTER.
8. Enter "1229" as the password for the automatic update mode and press ENTER.
NOTE: The automatic procedure password (1229) is the same for the Santa Fe.
9. The Hi-Scan Pro will establish communication.
NOTES:
^ The current ECM ID will be replaced by the new ECM ID.
^ To prepare for reprogramming in case of an error, write down the old and new ECM IDs displayed on the Hi-Scan Pro screen during the automatic update procedure.
^ The recorded ECM IDs will be used if the Hi-Scan Pro fails to automatically download the new ECM software.
^ If the Hi-Scan Pro does not download the program properly, use the Manual Update Procedure following this section.
WARNING: Do not interrupt the reprogramming at any time. The ECM will be rendered inoperative if the program does not download completely.
10. The Hi-Scan Pro reinitializes the ECM.
11. When the "REPROGRAMMING COMPLETED" message is displayed, check the new ECM ID displayed on the Hi-Scan Pro screen to verify that the correct ECM software has been downloaded. Refer to the "ECM SPECIFICATION TABLE" on page 9 of this article for the ECM ID listing. Turn the Hi-Scan Pro OFF and the process is complete.
12. When the reprogramming is completed successfully, turn the ignition to the OFF position, wait 15 seconds, then start the engine to check for proper operation.
13. Check for DTC using the Hi-Scan Pro with system software card and erase any DTC.
MANUAL UPDATE PROCEDURE:
NOTE: In the event menu option "01. EF 2.5 & 2.7 TiO2S HEATING [AUTO]" fails to download the new program, option "02. EF 2.5 & 2.7 TiO2S HEATING [ERROR]" must be used.
1. Turn the ignition to the ON position.
2. Turn the Hi-Scan Pro ON and press ENTER.
3. Select option "32. EF 2.5 & 2.7 TiO2S HEATING IMPROVEMENT" and press ENTER.
NOTE: Select option "33. SM 2.7 TiO2S HEATING IMPROVEMENT" if you are working on a Santa Fe.
4. Select option "02. EF 2.5 & 2.7 TiO2S HEATING [ERROR]" and press ENTER.
5. Select the ECM type which is correct for your vehicle by referring to the charts on page 4 of this TSB.
6. Enter the correct password after identifying the vehicle production date and by referring to the table on page 4 of this TSB. In addition, use the ECM IDs written down during the automatic procedure to confirm the correct ECM version. Then press ENTER.
WARNING: Be sure to input the correct password. If an incorrect password is selected, the correct ECM software will not be downloaded.
7. The Hi-Scan Pro will establish communication.
NOTES:
^ The Hi-Scan Pro displays the new ECM ID on the screen.
^ The program will take approximately 7 minutes to download completely.
WARNING: Do not interrupt the reprogramming at any time. The ECM will be rendered inoperative if the reprogram does not download completely.
8. The Hi-Scan Pro reinitializes the ECM.
9. When the "REPROGRAMMING COMPLETED" message is displayed, check the new ECM ID, displayed on the Hi-Scan Pro screen, to verify that the correct ECM software has been downloaded.
10. When the reprogramming is completed successfully, turn the ignition to the OFF position, wait 15 seconds, then start the engine to check for proper operation.
11. Check for DTC using the Hi-Scan Pro with system software card and erase any DTC.
EXPLANATION OF ERROR MESSAGE:
1. "INVALID PASSWORD": Please enter the correct password for the automatic update mode again (1229).
2. "REPROGRAMMING ERROR PLEASE WAIT FOR RETRY": An error occurred during reprogramming; the Hi-Scan Pro will retry the reprogramming automatically.
3. "THIS ECM IS DIFFERENT TYPE": The ECM on this vehicle is not the type subject to this reprogramming procedure.
4. "ALREADY REPROGRAMMED": The reprogramming has previously been done on this vehicle.
5. "REPROGRAM ERROR PLEASE CHECK THE SYSTEM": In this case you must reprogram manually by selecting menu option "02. EF 2.5 & 2.7 TiO2S HEATING ECM [ERROR]". (For the Santa Fe, choose "02. SM 2.7 TiO2S HEATING ECM [ERROR]").
VEHICLE EMISSION RECALL PROOF OF CORRECTION FORM
A Vehicle Emission Recall-Proof of Correction form must be filled out for all cars registered in California, Massachusetts, Vermont and Maine. California, Massachusetts, Vermont and Maine residents who own an affected vehicle will be required to possess a Vehicle Emission RecallProof of Correction form as evidence of voluntary service campaign completion when they apply for vehicle registration renewal.
WHAT TO DO WITH THE FORM:
Each customer whose vehicle is registered in California, Massachusetts, Vermont and Maine must be given a completed Vehicle Emission RecallProof of Correction form after the voluntary service campaign has been completed.
NOTE: This form MUST be completed by the Dealership's Service Manager using a permanent ink pen. A fine point pen is recommended. When filling in the information, copy the information directly from the vehicle, NOT the repair order. ALL INFORMATION MUST BE PRINTED AND NEAT.