Service Procedure
NOTE:Verify that the vehicle is subject to this campaign by checking the "Warranty Vehicle Information" screen via DCS Interactive or DCS Online.
For Sonata and XG350 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 (100 mm) 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, 100-120 Nm, 1000-1200 kg-cm)
12. Reinstall the rear muffler.
13. Lower vehicle.
For Elantra and Tiburon 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.
4. Remove the fuel tank pressure sensor mounting bracket bolt.
5. Install the vapor hose disconnected in step 3 to the lower nipple of the new valve.
6. Connect the upper hose from the new valve to the 3 way connector.
7. Install the fuel tank pressure sensor bracket to the body structure with the new valve bracket below it and tighten the bolt.
8. Raise the fuel tank and install the fuel tank bands and nuts.
Torque Specification:
Fuel Tank Band Nut
(40-50 lb-ft, 54-68 Nm, 550-690 kg-cm)
9. Lower the vehicle.