Recall - Vapor Recovery Valve Mis-Calibrated

GROUP:
Campaign

NUMBER:
015

MODEL:
Sephia

DATE:
October 2000

SUBJECT:
Recall Campaign: ORVR Valve Replacement

This bulletin provides information related to a recall campaign for 1998 and 1999 Sephia ORVR (On-board Refueling Vapor Recovery) valves. The ORVR valve in these vehicles may be mis-calibrated. A mis-calibrated ORVR valve could result in one or both of the following:

^ Difficulty in filling fuel tank completely.

^ Fuel spill back or spit-back during refueling (possible safety concern).

To correct this situation, Kia is recalling all affected 1998 and 1999 Sephia models for emissions reasons to replace the ORVR valve. Because of the possible safety concerns, KMA has agreed with NHTSA's request that this also be treated as a safety related recall.

* NOTICE
There is no charge to the customer for this repair. Under applicable law you may not sell or otherwise deliver any affected 1998 or 1999 Sephia until the ORVR valve has been replaced.

For California dealers, this recall is subject to the State Of California Registration Renewal/Emission Recall Enforcement Program implemented in 1992. Involved vehicles must have the recall service completed before registration renewal.

INSPECTION:





1. Open right rear passenger door and check for campaign completion label.

If label is present, campaign has already been done - NO ACTION IS REQUIRED.

2. If campaign completion label is not present, continue on to ORVR Valve Replacement Procedure.

ORVR VALVE REPLACEMENT PROCEDURE

1. Raise vehicle.








2. Remove rear exhaust system by removing two nuts at rear of main catalytic converter flange and disconnecting rubber mounts (5) from exhaust system hangers.





3. Remove 3 bolts holding charcoal canister to body. Leave hoses connected and suspend canister towards the right, using suitable strap or wire.

4. Support fuel tank using a suitable jack or lifting device.

* NOTICE
If fuel tank is more than 1/4 full, it must be drained to avoid possible spillage from fuel filler pipe and to reduce excessive weight while fuel tank is being removed and reinstalled.

!WARNING
Fuel vapors are highly flammable. Death or serious injury could result if they are ignited. Make sure there are no open flames or cigarette smoking in the area of the repair. Adequate ventilation is necessary to prevent a buildup of fumes which could ignite, causing fire or explosion.








Loosen and remove two bolts securing the tank straps to the body; lower fuel tank only so far as to allow access to the joint hose connecting the filler neck to the fuel tank. (Exhaust heat shield may be left attached to the RH tank strap.)

5. Using compressed air, blow loose dirt, etc. from area around ORVR valve.

6. Loosen filler neck joint hose clamp on the tank side and disconnect hose.





7. Lower tank carefully to where the top rear of the tank is just below the rear stabilizer bar.

Free ORVR and rollover vent lines by bending open the metal tabs on tank.

Release hose clamp, and disconnect vent hose from ORVR valve. Position hose over rear stabilizer bar.





8. Remove ORVR valve by turning it 1/4 of a turn counter clockwise and lifting up. Discard old valve.

9. Verify that ORVR seating surface in tank is clean.

10. Apply a small amount of petroleum based lubricant to ORVR seal ring and spring washer to facilitate installation.





Place new ORVR valve in tank opening with hose connection outlet positioned at three o'clock.

Push down on the valve to seat seal ring and compress spring ring, then rotate clockwise 1/4 of a turn until stop is felt and hose outlet is pointing to rear.





11. Re-connect vent hose to ORVR valve, and reposition hose clamp.

Secure vent lines in place by bending metal tabs on tank around lines.

12. Raise tank carefully until filler neck joint hose connection can be made.





Connect hose to tank, and tighten hose clamp.





13. Raise tank completely; adjust position as required to allow tank straps to be attached. Install and tighten two bolts attaching tank straps to body.

CAUTION
Ensure fuel lines or electrical connectors do not get pinched between tank and body.





14. Re-mount charcoal canister to body with 3 bolts and tighten.








15. Place a new gasket on the catalytic converter flange. Position exhaust system on converter studs and attach at least one rubber mount in the rear to support exhaust, then install catalytic converter flange nuts and attach remaining rubber mounts.

16. Lower vehicle.

* NOTICE
If fuel was removed, transfer back into vehicle.





17. Install campaign completion label on right rear door jamb as indicated in photo.

For California Dealers:





For vehicles sold in California, a supplied Vehicle Emission Recall Proof of Correction Form must be completed and given to each owner upon completion of the recall service for owner use as proof during renewal of vehicle registration

AFFECTED PRODUCTION RANGE:
1998 and 1999 Sephia models produced from October 17, 1997 to May 16, 1999.





PART NUMBER INFORMATION:





WARRANTY CLAIM INFORMATION: