Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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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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After examining the fuel pumps returned under claim for the above vehicles, it has been found that a high percentage of returns have no operating fault found with them. The normal complaint is “not pumping”, or “fuel starvation”. In some cases the fault may be cured when a new fuel pump is fitted, but returns shortly afterwards. There are two common causes of these symptoms on the vehicle, besides the fuel pump: 1) The Rubber Fuel Supply Pipe This may be perished or weakened, resulting in a partial or total collapse of the internal bore, restricting the fuel flow. The perishing of the pipe can also lead to air leaks on the suction feed to the fuel pump, so that the pump sucks air as well as fuel, reducing the lift efficiency of the fuel pump. 2) The In-Line Fuel Filter The filter should be changed at intervals of 20,000miles (32,000Km). Failure to do so will result in a build up of sediment particles blocking the filter, reducing the fuel flow. This is especially so on older vehicles where corrosion takes place within the fuel tank and metal feed pipes. In order to ensure that the fuel feed system operates at its full potential, it is recommended that both of the above items are checked, and/or replaced, before fitting a new fuel pump.

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On many PSA models fitted with the Hdi (common rail) engine it is necessary to service the particulate filter (FAP) system every 40,000 to 50,000 miles. This will be indicated via the instrument cluster in the form of a ‘Particulate’ system warning. The following components make up the FAP system: Control module (normally located in the cabin) Particulate filter (part of the exhaust system) Fluid reservoir (Integrated in the fuel tank) Pump Injector The FAP system was introduced on PSA vehicles back in the year 2000 when it was developed to reduce diesel particulate levels in engine emissions through filtration. The system operates by burning off particles caught in the filter which make up part of the exhaust system. To enable this ‘burning off’ process the exhaust gas temperature must be raised to approximately 500°C, this is achieved by changing the characteristics of the diesel before combustion by the means of an additive. The additive is held in a separate fuel reservoir (approx 5 litres) which is connected via a pump to an injector fitted into the diesel fuel system (normally in the fuel tank). A proportional amount of additive is injected under the control of the FAP ECU when the diesel tank is filled up, for this to be accurate the system needs to have information from the ‘Fuel level’ sensor to determine what quantity to inject. When the ‘Particulate’ warning lamp is displayed it is essential to diagnose the FAP system first to determine the problem. If the fault describes ‘Fluid level low’ or ‘Filter blocked’ then both areas need to addressed simultaneously as it is normal to find that when the reservoir is empty (approx 5L) then the filter has come to the end of its serviceable life. Please check specific Peugeot / Citroen information for service intervals and capacities,

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WARNING: Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material. 1. 2. 3. 4. 5. 6. 7. 8. Level the vehicle. Complete the “BEFORE REPAIR PROCEDURE”. Disconnect the negative battery cable. Remove the rear seat cushion. Remove the service hole cover. Remove the fuel pump unit. Siphon the fuel from the fuel tank. Remove the presilencer. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Complete the “AFTER REPAIR PROCEDURE”. Plastic Fuel Hose Removal Note CAUTION: The retainer must be replaced If removed from the fuel pipe without using the SST. Otherwise, effectiveness of the retainer will be reduced. 1. Inspect that the quick release connector joint area is tree of foreign material. 2. Clean as necessary. 3. Set the SST as shown and push into the quick release connector to disconnect the plastic fuel hose. 4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

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1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Release the fuel pressure. For additional information, refer to Section 310-00. 3. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 4. If removing the fuel tank or fuel pump module, use the special tool and siphon the fuel through the fuel filler hose into a suitable container. 5. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. 7. Turn the ignition key to the ON position to pressurize the fuel system. 8. Visually inspect the fuel system for leaks. Item 3: Fuel Filler Pipe Pin-Type Retainer Removal Note 1. Remove the LH rear wheel well inner splash shield. Item 7: Fuel Filler Pipe Removal Note 1. CAUTION: Some fuel will remain in the fuel filler pipe after draining the fuel tank. Carefully drain the filler pipe into an appropriate container. Separate the fuel vapor fresh air hose from the fuel filler pipe mounting bracket. Items 9, 10 and 18: Fuel Supply and Vapor Tube Quick Connect Fittings Removal Note 1. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube. NOTE: If the fuel tube or retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retainer clip legs. Once the retainer clip legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. Disconnect the fuel tube quick release coupling. Push the connector towards the tube to release pressure. Press the fuel tube quick release coupling button and pull the fuel tube to disconnect.