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Drive Cycle Recommendations NOTE: The following procedure is designed to execute and complete the evaporative emission repair verification drive cycle and to clear the Ford P1000, inspection and maintenance (I/M) readiness code. When the ambient air temperature is below 4.4°C (40° or above 37.8° (100° or the altitude is above 2,438 meters (8,000 feet), the EVAP monitor will not run. If the F) C F), P1000 must be cleared in these conditions, the powertrain control module (PCM) must detect them once (twice on some applications) before the EVAP monitor can be bypassed and the P1000 cleared. The EVAP bypassing procedure is described in the following drive cycle. 1. Most OBD II monitors will complete more readily using a steady foot driving style during cruise or acceleration modes. Operating the throttle in a smooth fashion will minimize the time necessary for monitor completion. 2. Fuel tank level should be between one-half and three-quarters full with three-quarters full being the most desirable. 3. The evaporative monitor can only operate during the first 30 minutes of engine operation. When executing the procedure for this monitor, stay in part throttle mode and drive in a smooth fashion to minimize fuel slosh. Drive Cycle Preparation NOTE: For best results, follow each of the following steps as accurately as possible. 4. NOTE: This step bypasses the engine soak timer and resets OBD II monitor status. Install the scan tool. Turn the key ON with the engine OFF. Cycle the key off, then on. Select the appropriate vehicle and engine qualifier. Clear all diagnostic trouble codes (DTCs) and carry out a PCM reset. 5. Begin to monitor the following PIDs: ECT, EVAPDC, FLI (if available) and TP MODE. Press Diagnostic Data Link, PCM, PID/Data monitor and record, press trigger to select each PID, then start. 6. Start the engine without returning the key to the OFF position. Preparation for Monitor Entry WARNING: Strict observance of posted speed limits and attention to driving conditions are mandatory when proceeding through the following drive cycle. 7. NOTE: This step allows engine warm-up and provides intake air temperature (IAT) input to the PCM. Idle the vehicle for 15 seconds. Drive at 64 km/h (40 mph) until the ECT is at least 76.7° (170° C F). 8. Is IAT above 4.4° (40°F) and below 37.8°C (100° C F)? If not, continue with the following steps but note that the EVAP Monitor Bypass portion of the drive cycle (step 13) will be required to bypass the EVAP monitor and clear the P1000. 9. NOTE: This step executes the heated oxygen sensor (HO2S) monitor. Cruise at 64 km/h (40 mph) for 60 seconds. 10. NOTE: This executes the EVAP monitor if IAT is above 4.4°C (40° and below 37.8° (100°F). F) C NOTE: To initiate the monitor, TP MODE should equal PT, EVAPDC must be greater than 75%, and FLI must be between 15 and 85%. NOTE: Avoid sharp turns and hills. Cruise at 72 to 104 km/h (45 to 65 mph) for 10 minutes. 11. NOTE: This step executes the ISC portion of the Secondary Air/CCM. Bring the vehicle to a stop. Idle with the transmission in DRIVE (for automatic transmission) or NEUTRAL (for manual transmission) for two minutes. Pending Code and EVAP Monitor Bypass Check 12. NOTE: This determines if a pending code is preventing the clearing of P1000. NOTE: If the EVAP monitor is not complete and IAT was below 4.4° (40° or above 37.8° (100°F) temperature range in Step 8, or the altitude is above 2,438 meters (8,000 feet), C F) C the EVAP Monitor Bypass (Step 13) must be carried out. Using the scan tool, check for pending codes. Conduct normal repair procedures for any pending code concerns. Rerun any incomplete monitor. EVAP Monitor Bypass 13. NOTE: This allows the bypass counter to increment to two. NOTE: Do not repeat Step 4. Park the vehicle for a minimum of eight hours. Repeat Steps 5 through 12.

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1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) line (3) from the canister.3. Reposition the EVAP canister hose clamp. 4. Remove the EVAP canister hose. 5. Disconnect the canister EVAP line from the fuel sender. 6. Squeeze the small retainer in front of the canister in order to disengage the canister. 7. Remove the EVAP canister. Installation Procedure Notice: Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle. Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes. Replace the vapor pipes with original equipment or parts that meet GM specifications. Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomers or GM 6163M on the hose. 1. Install the EVAP canister. 2. Squeeze the small retainer in front of the canister in order to engage the canister. 3. Connect the canister EVAP line to the fuel sender. 4. Install the EVAP canister hose. 5. Position the EVAP canister hose clamp. 6. Connect the EVAP line (3) to the canister. 7. Install the fuel tank.

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Some customers whose vehicles are operated in dusty type environments, such as farming or mining off-road type applications, may comment about the illumination of the check engine light, with a DTC of P0446 (Restricted/Blocked EVAP Vent Path) being set. Cause Dirt and dust intrusion into the EVAP canister vent hose assembly, resulting in restricted air flow, may cause this condition. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics for P0446 and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below.

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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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Following instructions apply to left cylinder head. Removing Remove ribbed belt => page 13-6. Remove toothed belt => page 13-10. Remove noise insulation panel (arrows). Unbolt left and right-side front exhaust pipes from exhaust manifolds. Unbolt exhaust system from transmission bracket. Place clean VW1306 receptacle or drain pan under engine. Remove filler cap from coolant expansion tank. WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. Unscrew drain plug (arrow) on left-side of radiator. Install drain hose to connection if necessary. Remove coolant drain plug on engine (arrow) using 3247 hex ball socket, and drain coolant. Remove intake air duct between mass air flow sensor and intake air elbow. Disconnect harness connectors for intake manifold tuning valve -3- and intake air temperature sensor -4-. Move wiring clear. Disconnect vacuum lines (arrows). Disconnect hose between Evaporative Emission (EVAP) canister purge regulator valve and throttle assembly at throttle assembly. Unbolt retaining plate for intake manifold tuning valve (bolts -2-). Disconnect connector on throttle assembly and disconnect vacuum hose on fuel pressure regulator. Disconnect harness connectors from camshaft adjustment valve and fuel injectors (arrows). Disconnect harness connectors from Engine Coolant Temperature (ECT) sensor and Camshaft Position (CMP) sensor (arrows). Cut open tie wraps on cylinder head cover, unclip wiring retainer on fuel rail and disconnect cylinder block breather from left and right-side cylinder head covers. Move hoses and wiring clear to rear. Remove 4 bolts for fuel rail on intake manifold. Unclip fuel supply and return lines from retainer. Move fuel rail together with fuel injectors clear toward side. Note: Cover the fuel injectors with a clean cloth. Disconnect spark plug wires (left-side). Unbolt bracket for ignition coils (4 bolts) and move clear to right together with ignition coils.