Recall - Fuel Cut Valve Installation

VOLUME
3

GROUP
Campaign

NUMBER
038 (Revised)

MODEL
Optima

DATE
June 2004

SUBJECT
Safety Recall: Optima Fuel Cut Valve Installation





This bulletin provides information related to 2002-2003 MY Optima installation of a fuel cut valve in addition to the fuel cut valve (rollover valve) already installed on the fuel tank. Some 2002-2003 Optima vehicles may contain a fuel tank assembly fuel cut valve that may not close properly. If a vehicle with a fuel tank assembly fuel cut valve that may not close properly were to roll over, fuel spillage could occur.

Use the procedures to install the new fuel cut valve.

* NOTICE
There is no charge to the customer for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2002-2003MY Optima until it has been repaired, pursuant to the procedures set forth in this bulletin.

INSPECTION PROCEDURE:





Open hood and check for 5C038 Campaign Completion Label on bulkhead above master cylinder.

^ If label exists, NO FURTHER ACTION IS REQUIRED.

^ If label DOES NOT EXIST, continue on to INSTALLATION PROCEDURE.

INSTALLATION PROCEDURE:





1. Raise vehicle on hoist and support left side of fuel tank.

2. Remove nut from left fuel tank strap.





3. Remove clamp and disconnect vapor hose from fuel cut valve at tee connector.





4. Connect upper hose from new fuel cut valve to tee connector and install clamp.





5. Connect hose from fuel tank to lower fitting on new fuel cut valve and install clamp.

6. Position fuel cut valve bracket onto fuel tank strap stud. Install fuel tank strap and nut, torque to 15-20 lb-ft. (20-27Nm)





7. Install SC038 Campaign Completion Label onto bulkhead above master cylinder.

FOR CALIFORNIA, MASSACHUSETTS, VERMONT; AND MAINE DEALERS:

VEHICLE EMISSION RECALL - PROOF OF CORRECTION CARD

A Vehicle Emission Recall - Proof of Correction card must be filled out for all vehicles registered in California, Massachusetts, Vermont, and Maine.

California, Massachusetts, Vermont, and Maine residents who own an affected vehicle will be required to possess a Vehicle Emission Recall - Proof of Correction card as evidence of voluntary service campaign completion when they apply for vehicle registration renewal.

WHAT TO DO WITH THE CARD:

Each customer whose vehicle is registered in California, Massachusetts, Vermont, and Maine must be given a completed Vehicle Emission Recall - Proof of Correction card after the voluntary service campaign has been completed.

Note:
This card MUST be completed by the Dealership's Service Manager using a permanent ink pen. A fine point pen is recommended. When filling in the information, copy the information directly from the vehicle, NOT the repair order. ALL INFORMATION MUST BE PRINTED AND NEAT.

DO NOT COMPLETE THE CARD UNLESS THE SERVICE CAMPAIGN WORK IS COMPLETED!





The copy of the card shown indicates the areas to be filled in.

Each area must be filled in.

AFFECTED PRODUCTION RANGE:

All 2002-2003MY Optima models with production dates from 10/1/01 thru 11/9/02.





PART NUMBER INFORMATION:

Note:
An initial inventory of the Fuel Cut Valve will be shipped to all dealers to coincide with the recall announcement.





WARRANTY INFORMATION: