engine cover & fuel line interference

1. Please ensure this bulletin is read and initialled by: -
Service / Parts
Manager
Warranty
Officer
Foreman /
Leading Hand
Technicians
SE02612 Page 1 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
1. DESCRIPTION
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This Technical Service Bulletin has been issued to notify the Dealer Network,
the release of:
Recall ‘21B003’
This recall relates to the inspection and insulation of the return fuel (diesel)
hose on a number of Santa Fe (CM) face lifted models, equipped with the
2.2L Diesel „R‟ series engine ONLY.
Hyundai Motor Company has informed that insufficient clearance may exist
between the engine cover assembly and fuel return hose, which if left
unattended, could result in interference between these components.
(Extended period of interference may result in a fuel leak).
Should a vehicle in the affected range report to your dealership, then follow
the service procedure below to rectify.
NOTE: If a vehicle is presented outside the affected range, please contact
HMCA Technical Department for further directions.
2. AFFECTED VEHICLES
Model: Santa Fe (CM) F/L, with 2.2L Diesel „R‟ engine
Affected VIN ranges: KMHSH81XNAU539565 ~ KMHSH81XNAU649864
KMHSH81XNBU653698 ~ KMHSH81XNBU785150
KMHSH81XNCU813227 ~ KMHSH81XNCU850129
KMHSH81XSAU535572 ~ KMHSH81XSAU696421
KMHSH81XSBU656910 ~ KMHSH81XSBU783701
KMHSH81XSCU785582 ~ KMHSH81XSCU858961
Affected production date range: 1st
September 2009 ~ 13th
December 2011
Technical Service Bulletin
Hyundai Motor Company Australia ABN: 58 008 995 588
394 Lane Cove Road Macquarie Park, NSW, 2113 P: (02) 8873 6444 F: (02) 8873 6326
Model: Santa Fe (CM) Issue Date: 5th
April 2012
TSB Type: Recall
Campaign
Number:
21B003 TSB Number: SE02612
Group: Fuel System
Parts
Availability:
In Stock Supersedes: SE01812
Subject: Engine Cover Interference – Recall 21B003

2. SE02612 Page 2 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
3. PARTS REQUIRED – (Via normal parts supply)
Part Number 31300-2B551QQH
RemarksPart Name Hose Assembly
Quantity 1
Contents
Only
required if
inner tube
exposed.
Step 5.3
2x Hoses 1x Clip 1x Strap
OR
Part Number 31300-2B552QQH
RemarksPart Name Clip & Strap
Quantity 1
Contents
Required
if inner
tube not
exposed.
Step 5.2
1x Clip 1x Strap
4. OPERATION CODE AND TIME
OP Code OP Name OP Time Claim Type
21B003R0
Engine Cover / Fuel Hose Interference
Inspection, with Installation of Clip & Strap
0.2 M/H
Recall 21B003
21B003R1
Engine Cover / Fuel Hose Interference
Inspection, with Replacement of Fuel Hose Ass‟y
0.3 M/H

3. SE02612 Page 3 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
5. SERVICE PROCEDURE
5.1 - Engine Cover / Fuel Hose Interference Inspection
1) Open the bonnet cover, and inspect
whether evidence of the fuel hose
(B) has been in contact with the
engine cover (A).
2) Prior to carrying out any
adjustments, measure the distance
between the fuel return hose, and
engine cover.
Minimum clearance required
between engine cover and top of
fuel hose: 20mm
1.1) If no contact with fuel hose is evident, proceed to step 5.2, Fuel
Hose Adjustment.
1.2) If contact with fuel hose is evident, with acceptable wear to fuel
hose lining (inner tubing not exposed), proceed to step 5.2, Fuel
Hose Adjustment.
1.3) If contact with fuel hose is evident, and inner fuel tubing is exposed,
proceed to step 5.3, Fuel Hose Adjustment and Replacement.
(Slight stretching of outer rubber shielding may be necessary)
1.4) Examples of acceptable wear to fuel hose;
Acceptable wear to fuel hose.
Adjust fuel line only.
Inner fuel tubing exposed.
Replacement of fuel line
mandatory.
20mm specification
Edge of engine cover

4. SE02612 Page 4 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
5.2 - Fuel Hose Adjustment
 Parts required „Clip & Strap‟ 31300-2B552QQH
1) Remove the engine cover (K).
2) Measure the distance between the
engine rocker cover and centre of
return fuel line.
Maximum distance: 55mm
3) If this measurement is more than
55mm, apply light pressure by
hand, and bend the return fuel hose
mounting bracket until specification
is achieved.

5. SE02612 Page 5 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
4) Use strap to tie both fuel hoses (E)
as shown in the adjacent picture by
tying them with the supplied strap.
Caution: The tying point should be located
within 80 mm from the clamp (F).
5) Once tied, cut and discard the
remaining excess part of the strap
(G).
Note: i) Securely tie the fuel hoses
together using the strap,
however ensure the fuel hoses
do not deform.
ii) When tying the strap, the
head of the strap should be
located to the front as shown
in the picture.
6) Align the three hoses at the existing
clip (H) in preparation for
installation of the new clip.
7) Install the new clip (J) to fuel hoses
nearby the existing clip (I) as
shown.

6. SE02612 Page 6 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
8) Reinstall the engine cover.
9) Confirm clearance between the
engine cover and the fuel hose
exceeds the minimum 20mm
required.
10) Should the 20mm clearance not be
achieved, repeat previous steps as
necessary, and then re-confirm
clearance.
11) Proceed to step 5.4 Campaign
Completion.
5.3 Fuel Hose Adjustment and Replacement
 If internal fuel tubing is exposed,
 Part required „Hose Assembly‟ 31300-2B551QQH
1) Switch off the engine and
disconnect the (-) battery cable.
2) Remove the engine cover (K).
3) Release the clamp (L).
4) Remove the fuel tube assembly
after releasing connecting parts
(M).
20mm

7. SE02612 Page 7 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
Caution: Place a towel (N) under the fuel
hose assembly, to prevent
contamination of surrounding
components with fuel.
5) Install the supplied fuel pipe
assembly to the engine.
Note: The supplied fuel pipe
assembly is equipped with a
clip and a strap (O).
6) Measure the distance between the
engine rocker cover and centre of
return fuel line.
Maximum distance: 55mm
7) If this measurement is more than
55mm, apply light pressure by
hand, and bend the return fuel hose
mounting bracket until specification
is achieved.

8. SE02612 Page 8 of 8
© HMCA 2012 – This Technical Service Bulletin is confidential and for internal Dealer Use only.
No part of this TSB is to be reproduced or made public without the express written consent of HMCA.
8) Reinstall all the removed parts in
reverse order of removal.
9) Confirm clearance between the
engine cover and the fuel hose
exceeds the minimum 20mm
required.
10) Should the 20mm clearance not be
achieved, repeat previous steps as
necessary, and then re-confirm
clearance.
11) Proceed to step 5.4 Campaign
Completion.
5.4 Campaign Completion
1) Affix a “Field Program Completed”
label onto the inner „A‟ pillar
(driver‟s side) using reference
number 21B003, your dealer code
and date completed in the required
fields.
Be sure to clean the contact area
prior to adhering label.
20mm