Engine Controls - Oxygen Sensor Wiring Damage

Group
36 - Engine Electrical

Number
02-36-034

Subject
2002 SONATA 2.7L V6 Oxygen Sensor Wire Rerouting

Date
12-2002

Model
Sonata 2002

DESCRIPTION:





Some 2002 Model Year SONATA vehicles with 2.7L V6 engines were produced with improperly routed Bank I Rear Oxygen sensor wiring.

This may cause the oxygen sensor wire to interfere with the generator "B+" terminal and cause damage to the oxygen sensor wiring.

This condition can be corrected by inspecting and rerouting the oxygen sensor wire using the service procedure described in this bulletin.

VEHICLES AFFECTED:

^ Model: 2002 SONATA vehicles with 2.7L V6 engines

^ Affected vehicle production date range: February 15, 2002 - April 29, 2002

SERVICE PROCEDURE:

Verify that the production date and VIN are within the affected range.

1. Open and secure the hood.

2. Inspect the oxygen sensor wire route.

A. If the vehicle is NOT equipped with ABS, the B1/S2 02 Sensor Wiring is visible from above the vehicle. If the sensor wire was routed correctly over the generator housing, no further action is required. Close the hood.





B. If the vehicle is equipped with ABS, the B1/S2 02 Sensor Wiring routing is not visible from the top. Lift the vehicle and examine the 02 Sensor wiring from below the vehicle. The pictures show the correct and incorrect wiring routing when viewed from below the vehicle.

If the sensor wire was routed incorrectly as shown, correct the wire routing by following the procedure in this TSB.

3. Write down the radio preset stations (AM, FM1 and FM2).

4. Remove the negative (-) battery cable

5. Route the sensor wire correctly by performing the following steps:

NOTE:
The directions below are for a vehicle equipped with ABS. If the vehicle is NOT equipped with ABS, these steps may be performed from above the vehicle.

A. Remove the plastic cover near the B1/52 02 sensor (10 mm socket, 2 bolts).





B. Remove the cap from the generator "B" terminal by using a right angle pick tool.





C. Remove the generator "B" terminal securing nut by using a 12 mm Socket on a 1/4" swivel head ratchet





D. Disconnect the generator "L" terminal connector.





E. Reroute the oxygen sensor wire over the generator housing as shown





F. Reconnect the generator "L" terminal.

G. Reinstall the generator "B" terminal nut and cap.

6. Reconnect the battery negative cable.

7. Reset the radio preset stations and set the clock to the correct time.

8. Close the hood.





CAMPAIGN CLAIM INFORMATION:

NOTE
Submit claims using the Campaign Claim Screen.

NOTE
If the oxygen sensor requires replacement, please submit a claim for the oxygen sensor replacement under a separate claim. Normal warranty applies to oxygen sensor replacement.