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1 – AZERA KEY CUTTING PROCEDURE The Azera is equipped with high security internally cut keys. This section of the TSB provides information on how to order complete pre-cut key sets from an HMA Parts Distribution Center. These special high security key blanks cannot be cut by conventional key cutting machines and must be either ordered pre-cut from your Hyundai Motor America Parts Distribution Center or be cut on a specific key cutting machine. Azera key blanks can only be code cut by the BD Laser, a machine produced by Barnes Distribution. This machine may not be available at all Hyundai Dealerships, therefore the option to order them pre-cut from an HMA PDC has been made available. PROCEDURE: When an owner loses an Azera immobilizer key, the customer has two options to replace the lost key. Both options require that the customer bring the vehicle and any remaining keys to an authorized Hyundai dealer. Option # 1 The customer can use any remaining key originally supplied with the vehicle to drive to an authorized Hyundai dealer and request that a new key or key set be cut and programmed. It is important that the customer bring any remaining keys with them to the dealership. Any key that is not programmed (or re-programmed in the case of originally supplied keys) in the same operation will no longer start the vehicle. Option # 2 The customer can have the vehicle towed to an authorized Hyundai dealer and request that a new key or key set be cut and programmed. Again, it is important that the customer bring any remaining keys with them to the dealership. Any key that is not programmed (or re-programmed) in the same operation will be unable to start the vehicle. 1. If the Hyundai dealer does NOT have a Barnes Distribution BD Laser, they MUST call the Hyundai Motor America Parts Call Center at 1-800-545-4515 and make a request (order) for Azera immobilizer keys to be cut. NOTE: Azera immobilizer key blanks can be ordered either in singles (i.e. 1- master) or complete key sets (i.e. 2-master keys and 1-sub or valet key). However, HMA Parts Distribution Centers will only pre-cut complete key sets upon request. They will NOT cut single master keys. 2. The Hyundai dealer MUST provide the following information to the HMA Parts Call Center. • VIN • Key Code • Dealer Code • Dealer Address (exact shipping address) • Dealer Contact (exact name of who the key should be delivered to) • Contact Phone Number and Extension 3. The HMA PDC will expedite the shipping of the key(s) to the dealership address as provided in step 2. 4. Once the dealership has taken delivery of the key(s), the key(s) must be programmed to the vehicle using a Hi-Scan Pro tool. NOTE: The Azera is equipped with immobilizer anti-theft technology that will not allow the newly cut keys to start the vehicle unless they have been first programmed to the vehicle.

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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.

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1. 2. 3. 4. 5. Drain the coolant and disconnect the upper radiator hose. Remove the breather hose (between the air cleaner and the rocker cover). Remove the air-intake hose. Remove the vacuum hose, fuel hose and coolant hose. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion. Remove the ignition coil. Remove the surge tank. Remove the intake manifold. Remove the heat protector and exhaust manifold assembly Remove the coolant pump pulley and the crankshaft pulley. Remove the timing belt cover. 6. 7. 8. 9. 10. 11. Zoom Sized for Print 12. Move the timing belt tensioner pulley toward the coolant pump and temporarily secure it. 13. Remove the timing belt. 14. Remove the rocker cover. 15. Remove the cylinder head assembly. The cylinder head bolts should be removed using Special Tool, Cylinder Head Bolt Wrench (09221-21000), in the sequence as shown in the illustration. 16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface. NOTE: 1. Make sure that the gasket pieces do not fall in to the engine. INSPECTION 1. Check the cylinder head for cracks, damage and coolant leakage. 2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. 3. Check the cylinder head surface for flatness using a straight edge in the direction of A, B, …as shown. If flatness exceeds service limit in any direction, replace the cylinder head, or lightly machine the cylinder head surface. Cylinder head flatness Standard value: Less than 0.03 mm (0.0012 inch) Limit: 0.08 mm (0.0031 inch) REASSEMBLY 1. Clean all gasket surfaces of the cylinder block and the cylinder head. 2. Install a new cylinder head gasket onto the cylinder head assembly. Do not apply sealant to the gasket and do not reuse the old cylinder head gasket.

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DESCRIPTION The following vehicles share common transaxle Diagnostic Trouble Codes (DTC): • 1996-2005 Accent • 1996-2000 Elantra • 1997-2001 Tiburon Elantra and Tiburon vehicles produced beginning 6/1/99 and 2000-2005 Accent vehicles use a valve body with six solenoids and have several new DTCs. DTC information can be found in the shop manuals, TSBs and Engine Fault Code Diagnostic Manual (OBDII Manual) listed below: DTC P0501 Vehicle speed sensor range DESCRIPTION P0703 Stop lamp switch – Open/short P0705 Range switch signal problem P0707 Range switch – open circuit P0708 Range switch – short circuit P0710 A/T fluid temperature sensor P0711 A/T temperature sensor – rational- ity check DTC P0712 A/T temperature sensor signal – open/short P0713 A/T temperature sensor signal – open/short P0717 No pulse generator A signal P0722 No pulse generator B signal P0727 Engine speed signal – open circuit DESCRIPTION P0731 1st gear incorrect ratio P0732 2nd gear incorrect ratio P0733 3rd gear incorrect ratio P0734 4th gear incorrect ratio P0740 Torque converter clutch control system problem P0741 Damper clutch stuck off P0742 Damper clutch stuck on P0743 Damper clutch control solenoid valve – open/short P0745 Pressure control solenoid valve A – open/short, TR-9 P0747 Pressure control solenoid valve – open P0748 Pressure control solenoid valve – short P0750 Shift control solenoid valve A – open/short P0752 Shift control solenoid valve A – open P0753 Shift control solenoid valve A – short P0755 Shift control solenoid valve B – open/short P0757 Shift control solenoid valve B – open P0758 Shift control solenoid valve B – short

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DESCRIPTION: On some vehicles the ambient temperature displayed on the climate controller may differ from the actual outside temperature by more than 5-10oF. An updated ambient temperature sensor is available to improve this condition. This TSB provides the procedure to install the updated ambient temperature sensor located in front of the radiator/condenser. • Model / Affected vehicle production date range: • Azera (TG): Produced Job #1 – January 8, 2006 • Sonata (NF): Produced Job #1 – January 8, 2006 REPLACEMENT PROCEDURE: 1. Unfasten the ambient temperature sensor mounting bolt. 2. Remove the ambient temperature sensor by disconnecting the wiring connector. 3. Connect the wiring connector to the new sensor. 4. Tighten the ambient temperature sensor mounting bolt. 5. Reset the A/C control head after ambient temperature sensor replacement. • Azera – Remove for 15 seconds the Power Connector Fuse (30 amp) from the passenger compartment junction block and replace. • Sonata – Remove for 15 seconds the Power Connector 2 Fuse (15 amp) from the passenger compartment junction block and replace.