2002-2003 HYUNDAI SONATA FUEL TANK ASSEMBLY VALVE INSTALLATION
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Some of the vehicles affected by this campaign may contain a fuel tank assembly valve that may not close properly. This TSB provides the procedure to remedy this condition by installing an additional fuel tank assembly valve. For Sonata and XG350 vehicles (Please see pages 8-10 for Elantra and Tiburon vehicles): 1. Raise the vehicle. 2. Remove the three muffler hangers and support the rear muffler after it has been lowered 6 inches. NOTE: Do not allow the muffler to hang unsupported. Do not lower the muffler more than 6 inches. 3. Remove the rear suspension crossmember mounting bolts and lower the suspension crossmember. 4. Support the fuel tank using a jack stand. 5. Remove the left rear fuel tank band nut and lower the band from the mounting stud. 6. Disconnect the vapor hose from the ‘Y’ shaped tube. 7. Cut about 4 inches (100mm) from the end of the vapor hose as shown. Discard the 4 inch piece that you have removed. 8. Install the new valve bracket mounting hole over the fuel tank band stud and connect the cut end of the vapor hose to the lower nipple of the new valve. NOTE: The valve must be positioned above the mounting bracket, as shown. 9. Connect the upper hose from the new valve to the ‘Y’ shaped tube where the vapor hose was removed. 10. Install the fuel tank band over the valve bracket and tighten the nut. Torque Specification: Fuel Tank Band Nut (40-50 lb-ft, 54-68 Nm, 550-690 kg-cm) 11. Support the rear suspension using a crossmember jack. Carefully raise the suspension being sure not to make contact with the fuel tank. Tighten the four suspension mounting bolts after aligning the bolt holes and torque to specification. Torque Specification: Rear crossmember to body mounting bolt (74-88 lb-ft, 100-120Nm, 1000-1200kg-cm) 12. Reinstall the rear muffler. 13. Lower vehicle. For Elantra and Tiburon vehicles (Please see pages 3 – 7 for Sonata and XG350 vehicles): 1. Raise the vehicle. 2. Support the fuel tank using a jack stand and remove the rear fuel tank band nuts and lower the bands from the mounting studs. Using the jack, lower the fuel tank about 4 inches (100 mm) to obtain working space. 3. Disconnect the vapor hose in between the valve and the 3 way connector.
Some of the vehicles affected by this campaign may contain a fuel tank assembly valve that may not close properly. This TSB provides the procedure to remedy this condition by installing an additional fuel tank assembly valve. For Sonata and XG350 vehicles (Please see pages 8-10 for Elantra and Tiburon vehicles): 1. Raise the vehicle. 2. Remove the three muffler hangers and support the rear muffler after it has been lowered 6 inches. NOTE: Do not allow the muffler to hang unsupported. Do not lower the muffler more than 6 inches. 3. Remove the rear suspension crossmember mounting bolts and lower the suspension crossmember. 4. Support the fuel tank using a jack stand. 5. Remove the left rear fuel tank band nut and lower the band from the mounting stud. 6. Disconnect the vapor hose from the ‘Y’ shaped tube. 7. Cut about 4 inches (100mm) from the end of the vapor hose as shown. Discard the 4 inch piece that you have removed. 8. Install the new valve bracket mounting hole over the fuel tank band stud and connect the cut end of the vapor hose to the lower nipple of the new valve. NOTE: The valve must be positioned above the mounting bracket, as shown. 9. Connect the upper hose from the new valve to the ‘Y’ shaped tube where the vapor hose was removed. 10. Install the fuel tank band over the valve bracket and tighten the nut. Torque Specification: Fuel Tank Band Nut (40-50 lb-ft, 54-68 Nm, 550-690 kg-cm) 11. Support the rear suspension using a crossmember jack. Carefully raise the suspension being sure not to make contact with the fuel tank. Tighten the four suspension mounting bolts after aligning the bolt holes and torque to specification. Torque Specification: Rear crossmember to body mounting bolt (74-88 lb-ft, 100-120Nm, 1000-1200kg-cm) 12. Reinstall the rear muffler. 13. Lower vehicle. For Elantra and Tiburon vehicles (Please see pages 3 – 7 for Sonata and XG350 vehicles): 1. Raise the vehicle. 2. Support the fuel tank using a jack stand and remove the rear fuel tank band nuts and lower the bands from the mounting studs. Using the jack, lower the fuel tank about 4 inches (100 mm) to obtain working space. 3. Disconnect the vapor hose in between the valve and the 3 way connector.
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