Engine Controls - MIL ON/DTC's P2135/P0638
Group: FUEL SYSTEMNumber: 10-FL-010
Date: AUGUST 2010
Model: EN VERACRUZ, CM SANTA FE,
TG AZERA, EP ENTOURAGE,
NF SONATA, BH GENESIS
Subject
DTC P2135/P0638 OR COLD ENGINE RPM FLUCTUATION - TPS REPLACEMENT&
ECM UPDATE
NOTE:
This bulletin revises TSB 09-FL-003-2 to add the Genesis Sedan (BH) model to the applicability list. It also provides instructions to select the most recent available ECM Update Events #166-178 or any higher event numbers if they become available in the future.
DESCRIPTION:
Symptom/Condition:
Some 2.7L, 3.3L or 3.8L engines in models identified in the applicability list may experience one or more of the following conditions:
^ DTC P2135: Throttle position sensors 112 voltage correlation
^ DTC P0638: Throttle actuator control range/performance
^ RPM fluctuation while engine is cold (DTC not set)
NOTE:
Should either of the above DTC occur, the vehicle would have operated in limited power "limp home" mode and stored the following DTC in the ECM:
^ DTC P1295: ETC System Malfunction - Power Management
^ DTC P2106: ETC System Malfunction - Forced Limited Power
APPLICABILITY:
^ 2007-2009 EN Veracruz
^ 2007-2009 CM Santa Fe
^ 2006-2009 IG Azera
^ 2007-2008 EP Entourage
^ 2006-2009 NF Sonata with 3.3L Engine only
^ 2009-2010 BH Genesis Sedan
REPAIR ACTION:
^ Replace the Throttle Position Sensor (TPS)
^ Perform the ECM software update.
NOTE:
Always perform a GDS ECM Update by Automatic Mode first as it performs error checking to ensure the correct data is flashed into the vehicle. Always select the latest available ECM Update event data at time of your update.
NOTE:
Do not use ECM Update Manual Mode unless you experience a failure during the reflash process. It is essential under manual mode that the correct ECM is selected for the vehicle. If an incorrect ECM is selected, the car may not run. Most vehicles do not have an immobilizer so one of the NON IMMO ECMs should be selected for these vehicles.
PARTS REQUIRED:
Order the TPS part kit according to the applicable engine:
ECM ROM ID INFORMATION:
NOTE:
This TSB applies if your incident vehicle ROM ID is found in the PREVIOUS column of the below ROM ID Table.
NOTE:
The ROM ID in the NEW column was the latest available ROM ID at the date of this TSB publication however, you may select a later event number if one is shown in the ECM update list even if it describes another issue. This would generate a more recent ROM ID than shown below but it also includes the update from this TSB.
NOTE:
K-Line and CAN are different scantool communication protocols. CAN is faster for an ECM update than K-Line.
SERVICE PROCEDURE:
TPS REPLACEMENT PROCEDURE
NOTE:
The below procedure is performed on an AZERA (IG) 3.3L vehicle, but there is no need to remove ETC assembly for TPS replacement on all affected vehicle models.
1. Remove the engine cover, the air intake hose and the air cleaner upper cover.
2. Disconnect the IPS connector.
3. Remove the 3 IPS mounting bolts (1-20).
4. Replace the IPS, 0-ring and 3 bolts with the new ones.
NOTE:
Only 3 of the 4 available mounting holes are used.
CAUTION:
^ Apply clean engine oil around a new 0-ring before installing a new TPS.
^ Align the TPS terminals (below picture) with the mating motor terminals before installing a new TPS.
ECM UPDATE PROCEDURE
GDS SYSTEM AND ECM UPDATE PRECAUTIONS:
CAUTION:
Please verify the following items before performing the ECM update:
^ Make sure the vehicle's battery has reasonable charge. If the vehicle has been in storage, run the engine to ensure an adequate battery charge state for reliable update results. The ECM Update procedure contains a check to verify that battery voltage is above 12 volts to allow the procedure to occur.
^ The USB cable must be used for ECM Update between the GDS and VCI. The procedure will not work in VCI wireless mode.
^ Make sure the GDS laptop battery indicator in the lower right tray icons has 50% or more charge (half bar on the battery symbol). Charge the laptop battery with the AC adaptor cable if the charge is less than 50%.
^ Turn off all lamps (do not leave head lamp switch in auto mode) and all accessories (including heater, NC, blower, radio, seat warmer, defroster, etc.) to prevent battery discharge during the update.
^ Perform update with the ignition switch in the ON position.
^ Be careful not to disconnect any cables connected to the vehicle or scan tool during the update.
^ Do not start the engine during update.
^ Do not turn off the ignition switch during update.
INTERNET UPDATE OF GDS SOFTWARE VERSION:
NOTE:
This GDS update may be necessary to ensure your GDS has the latest possible ECM Updates.
1. Close the GDS program and restart it with internet connected to the GDS.
2. Wait for the following GDS Update Program to launch within approximately a minute. It will inform you if there is an update as shown below.
3. If update is available press OK and follow instructions to update the GDS software version followed by the VCI firmware level if it also exists.
NOTE:
You must have VCI connected to GDS by USB cable to update the VCI.
4. Perform Download followed by Update Start and then Exit when completed..
GDS AUTO MODE ECM UPDATE PROCEDURE:
1. Turn the vehicle's ignition key to the ON position.
2. Select ECU Upgrade on the initial GDS home page screen. If you are not at the home page double click at GDS at top left of the screen to go back to home page.
3. GDS will automatically determine the vehicle information based on the VIN it reads from the vehicle's ECM, then select Engine Control as system and OK.
4. Select Auto Mode then ENGINE then OK so the ROM ID will be read:
5. After reading the ROM ID if there is an available update it will display a screen with the available updates for the vehicle. Select the latest available (highest number) update event even if it describes another issue. After clicking the Upgrade button then click OK.
NOTE:
*Event # 166~178 as shown in the table above were latest events at time this TSB was issued. However be sure to select the highest number event available in the list even if it describes another issue. It will ensure the vehicle receives latest possible available ECM data including the fix for this TSB.
6. This screen is example only. Your screen will show the current ROM ID and latest ROM ID for update based on the event that you select. Choose the latest available (highest number) event as explained in the prior note.
NOTE:
An error message may appear instead of the above if the ECM Update
had already been completed or is not available for your vehicle.
7. After selecting the Upgrade button the vehicle battery voltage is checked to make sure it is at least 12 volts required to ensure reliable update results. Select OK if the results indicate voltage is above 12 volts.
CAUTION:
If voltage is below 12 volts, then select Cancel and run the engine at idle for at least 10 minutes to ensure an adequate battery charge state for reliable update results.
8. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be displayed. Turn the ignition key OFF for 10 seconds, place it back in the ON position and then select OK.
9. Select OK on the final screen, which indicates update is complete.
10. For EN Veracruz after update is completed, perform the VIN writing procedure or immobilizer key teaching procedure on the affected vehicles where it is referenced in the "ECM ROM ID INFORMATION "table earlier in this TSB.
11. Check for and erase DIG found in each system of ENGINE, A/T, ABS/ECS, and EPS as a result of temporary loss of CAN communication during the ECM Update.
12. Start the engine to confirm proper operation of the vehicle.
GDS MANUAL MODE ECM UPDATE PROCEDURE:
NOTE:
Manual Mode ECM Update is intended to be used only if Auto Mode ECM Update had failed after the progress bar began during the update.
IMPORTANT:
You must reset the ECM by disconnecting the ECM connectors for 10 minutes and then reconnecting them before trying the Manual Mode ECM Update.
1. Turn the vehicle's ignition key to the ON position.
2. Within the ECU Upgrade screen, select ENGINE, Manual Mode, and then select the appropriate event number from the table provided in Auto mode.
3. Select the appropriate control unit part number with reference to the ROM ID Information Table and then perform Upgrade.
NOTE:
This screen is example only. Be careful to select the correct ECM part number using ROM ID table to help. If in doubt remove ECM to read the part number. It is critical in manual mode to select the correct system and password.
4. Enter the Event password from the table below and then select OK.
5. If voltage is below 12 volts, then select Cancel and run the engine at idle for at least
10 minutes to ensure an adequate battery charge state for reliable update results.
6. Updating will occur until 100% is reached on the bar graph, then the confirmation screen will be displayed. Turn the ignition key OFF for 10 seconds, place it back in the ON position and then select OK.
7. Select OK on the final screen, which indicates update is complete.
8. Check if any incidental Diagnostic Trouble Codes (DTC) have been created by the update and clear the DTC (5) present.
9. Start the engine to confirm proper operation of the vehicle.
WARRANTY INFORMATION: