Page 1 of 35 Dear 2001-2003 Elantra or 2003 Tiburon Owner: This
Contents
1. July 17 2009 Itis IMPORTANT TO SUBMIT A CAMPAIGN CLAIM FOR EACH VEHICLE SERVICED so your dealership can be compensated for your work and Hyundai can maintain accurate records of campaign completions LEGAL LIABILITY NOTICE You are required to keep confidential any and all information and documents provided to you by Hyundai Motor America in the conduct of carrying out work for this recall campaign Hyundai Motor America dealers may use owner information provided for the recall campaign only for the purpose of conducting and performing this recall campaign and for no other purpose Page 3 of 35 Hyundai appreciates your cooperation and support Questions may be directed to your District Parts and Service Manager or Warranty HELPREP line at 1 877 446 2922 HYUNDAI MOTOR AMERICA Page 4 of 35 Technical Service HYUNDAI Bulletin CAMPAIGN Number 09 01 022 Subject Date XD ELANTRA GK TIBURON FRONT LOWER JULY 2009 CONTROL ARM AND FRONT SUBFRAME Model CORROSION TREATMENT CAMPAIGN 091 ELANTRA XD TIBURON GK CIRCULATE TO IMPORTANT DEALERS MUST PERFORM THIS CAMPAIGN ON ALL AFFECTED VEHICLES WHENEVER AN AFFECTED VEHICLE IS IN THE SHOP FOR ANY MAINTENANCE OR REPAIR IMPORTANT WHEN A VEHICLE ARRIVES AT THE SERVICE DEPARTMENT ACCESS HYUNDAI MOTOR AMERICA S WARRANTY VEHICLE INFORMATION SCREEN VIA WEBDCS TO IDENTIFY OPEN CAMPAIGNS DESCRIPTION e Some 2001 2003 Elantra XD and 2003 Tiburon GK ve2. NOTE Perform toe adjustment if necessary NOTE Spec GK Front 042 mm 0 08 0 08 in NOTE Spec XD Front 4 3 1 mm 0 16 12 04 in Page 26 of 35 EP Hyunan Technical Service CL Bulletin e FRONT LOWER CONTROL ARM INSPECTION AND REMOVAL 1 Lift up the vehicle 2 Lightly strike the right and left front lower control arms thoroughly with a hammer CAUTION Be careful DO NOT strike the front lower control arms too hard to prevent deformation damage Page 27 of 35 3 Inspect the lower control arms for corrosion perforation The photo at the right shows corrosion perforation CAUTION Inspect for corrosion perforation throughout the right and left front lower control arms including the sides NOTE If there is any corrosion perforation on either the right or left front lower control arms replace both right and left front lower control arm assemblies following the applicable shop manual If no perforation exists go to the next step to further inspect the front lower control arms for corrosion 4 Put a marking point F on the left front lower control arm as indicated in the photo 5 Put a marking point on the right front lower control arm at the same position as the left side Page 28 of 35 A HYUNDAI Technical Service Bulletin Ball joint outer end Page 29 of 35 6 Center the 12mm drill bit on the mark F and drill a hole on the left front l
3. py HYUNDAI Technical Service a Bulletin 3 Remove fragments of rust from the inside of the front lower control arms by following the detailed procedures below a Strike right and left front lower arms thoroughly with a hammer Insert a flexible magnet through all the holes and remove fragments of rust Insert the air gun into the inside of the front lower control arms through all the holes and blow out rust from inside the lower control arms e Air guns required d Repeat steps from a to c more than 2 times Group CAMPAIGN Number 99 91 0922 Page 33 of 35 Pour about 150cc of cavity wax into the injection gun reservoir Spray cavity wax into the inside of the right and left front lower control arms through all the holes until wax drains through the holes CAUTION 1 Protect yourself by wearing goggles a respirator gloves etc CAUTION 2 Insure proper ventilation of your working area CAUTION 3 Be careful NOT to contaminate nearby parts and panels with wax or undercoating 6 Spray undercoating around the holes WARRANTY CLAIM INFORMATION XD Elantra Produced from Job 1 through Jan 13 2003 Subframe Front Lower Control Arm Op Code Description 91B021R0 Subframe Lower Arm Replacement 91B021R1 Subframe Replacement Lower Arm Inspection amp Wax Application 91B021R2 Subframe Replacement Lower Arm Inspection amp Replacement 91B021R3 Subframe Wax Appli
4. Service Bulletin 2 Put a marking point on the right side member at the same position as the left side Page 15 of 35 3 Put 2 marking points D E on the left side of 2 member as indicated in the photo D 10mm from the first inflection point of press bending line yellow dotted line E 5mm from the second inflection point of press bending line yellow dotted line 1 Member 4 Put 2 marking points on the right side of 2 member at the same positions as the left side Page 16 of 35 gt HYUNDAI Technical Service CAMPAIGN Bulletin 5 Center the 40mm hole saw on the mark C and drill a hole on the left side member 6 Repeat this procedure for the right CAUTION Protect yourself by wearing goggles a respirator gloves etc Page 17 of 35 7 Remove burrs from around both the upper and lower openings of the drilled holes with a file and remove remnants of rust from around the holes prior to wax application 8 Center the 20mm hole saw on the mark D and drill a hole on the right side member 9 Repeat this procedure for the left 10 Chuck a drill bit 8mm in diameter to a drill Center the drill bit on the mark E and drill a hole on the left side member 11 Repeat this procedure for the right Press Bending Line Page 18 of 35 12 Remove fragments of rust from the inside of the subframe by following the detailed procedures below a Strike the subframe tho
5. AI DEALER PRINCIPALS GENERAL MANAGERS ALL HYUNDAI DEALERSHIP SERVICE MANAGERS ALL HYUNDAI DEALERSHIP PARTS MANAGERS ALL HYUNDAI DEALERSHIP SALES MANAGERS SUBJECT Recall Campaign 091 Front Lower Control Arm and Front Subframe Corrosion TSB 09 01 022 Hyundai Motor America is conducting a Customer Notification for inspection and rust proofing treatment or replacement of the front lower control arms and front sub frame on certain 2001 2003 model year Elantra and 2003 Tiburon model year vehicles This campaign provides a procedure for the inspection and rust proofing treatment or replace ment of the front lower control arms and front subframe In order to identify only those vehicles affected by Campaign 091 it will be necessary to access Hyundai Motor America s Warranty Vehicle Information screen via WEBDCS before starting the repair The Warranty Vehicle Information screen will identify affected vehicles with an open Campaign 091 Dealer Letter Customer Letter and Technical Service Bulletin 9 01 022 will be posted on Hyundai s Website July 10 2009 All Hyundai dealers will be shipped a supply of the following materials in their weekly parts shipments as part of the Subframe Trailing Arms Front Lower Control Arms campaigns 1 Tool kit s 2 Chemical kit additional chemicals can be ordered from your facing PDC as more chemicals are required Customer notification letters will be mailed in weekly flights starting Friday
6. BFRAME REPLACEMENT PROCEDURE So Original Procedure Revised Procedure Procedure To replace the crossmember It is possible to remove the cross remove it simultaneously with the member without detaching the steering gearbox steering gearbox from the vehicle DO NOT remove the steering gear box for the crossmember replace ment Lift the vehicle off the ground Remove the right and left front wheels Remove the right and left wheel side covers A Page 23 of 35 4 Remove the under cover 5 Remove the front pipe B 6 Remove the right and left lower control arm ball joint mounting nuts C 7 Remove the right and left stabilizer link lower ends D from the stabilizer bar 8 Remove the power steering pipe line mounting bolts E Page 24 of 35 bi HYUnNpaIr Technical Service lt L Bulletin Number 99 91 0922 9 Remove the RH power steering gear mounting bolts F 10 Remove the LH power steering gear mounting bolts G 11 Remove the bolts H holding the front and rear roll stoppers to the brackets Page 25 of 35 12 Remove the right and left crossmember rear stays l 13 Unfasten the 2 washer tank lower mounting bolts J 14 Support the crossmember with a jack 15 Removing the 4 crossmember mounting bolts K detach the crossmember from the steering gearbox and then remove the crossmember 16 Install in reverse order of removal
7. Dear 2001 2003 Elantra or 2003 Tiburon Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Hyundai has decided that a defect which relates to motor vehicle safety exists in certain model year 2001 through 2003 Hyundai Elantra vehicles that were produced during the period begin ning June 30 2000 through January 13 2003 and certain model year 2003 Hyundai Tiburon vehicles produced beginning on October 26 2001 through January 13 2003 This recall affects such vehicles registered in and operated in Connecticut Delaware Illinois Indiana Iowa Maine Maryland Massachusetts Michigan Minnesota Missouri New Hampshire New Jer sey New York Ohio Pennsylvania Rhode Island Vermont West Virginia and Wisconsin and the District of Columbia the Salt Belt Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days What is the problem During winter months large quantities of salt are used to de ice roads in the Salt Belt states noted above Road salt may result in internal corrosion and thinning of the steel in the front lower control arms In severe cases the corrosion may progress to the point where the lower control arm s upper and lower panels become perforated A perforated front lower control arm may fracture between its ball joint attachment and the forward and rearward pivot att
8. achments to the chassis This could affect your control over the tire and wheel assembly Reduced control of the front wheel direction may increase the risk of a vehicle crash without warning What will Hyundai do We are asking you to schedule an appointment as soon as possible to take your vehicle to your Hyundai dealer The Hyundai dealer will inspect the front lower control arms for corrosion damage If specified levels of internal corrosion damage are found the front lower control arms will be replaced with new front lower control arms incorporating additional holes in the upper and lower panels If your front lower control arms do not require replacement the dealer will add drainage holes to the front lower control arms and will treat the front lower control arms with rust proofing material to arrest the internal corrosion process In addition to treating the front lower control arms the Hyundai dealer will inspect the front subframe of your vehicle for signs of corrosion that could potentially progress and ultimately affect vehicle performance This additional inspection is a precautionary measure to offer improved drainage in the front subframe If the dealer finds a specified level of corrosion dam age the dealer will replace the front subframe Otherwise the dealer will treat the front sub frame with rust proofing materials and add drainage holes Page 1 of 35 Both procedures will be performed at no charge to you You should pla
9. cation Lower Arm Replacement 91B021R4 Subframe Wax Application Lower Arm Inspection amp Wax Application 0 9 91B021R5 Subframe Wax Application Lower Arm Inspection amp Replacement Page 34 of 35 A HYUNDAI Technical Service Bulletin GK Tiburon Produced from Job 1 through Jan 13 2003 Subframe Front Lower Control Arm a Time Op Code Description 91B021R6 Subframe Lower Arm Replacement 91B021R7 Subframe Replacement Lower Arm Inspection amp Wax Application 91B021R8 Subframe Replacement Lower Arm Inspection amp Replacement 91B021R9 Subframe Wax Application Lower Arm Replacement 91B021RA Subframe Wax Application Lower Arm Inspection amp Wax Application os 91B021RB Subframe Wax Application Lower Arm Inspection amp Replacement NOTE Submit claims using Campaign Entry Screen NOTE Each applicable claim includes a sublet amount for chemical hole saw and drill bit reimbursement NOTE Reimbursement for the Wax Injection Gun will be processed in Dealership s Parts statement PARTS SCRAP INFORMATION 1 Lower Arm Subframe Inspection and Replacement without drilling holes It is required that digital photos be taken of the replaced parts as well as the VIN plate These pictures must be attached to their respective repair order for DPSM review The removed lower arms subframe may be scrapped 2 Lower Arm Subframe Inspection and Replacement with drilling holes It is require
10. d to retain the core sample and repair information for DPSM review The removed lower arms subframe may be scrapped 3 Lower Arm Subframe Inspection and Wax Application It is required to retain the core sample and repair information for DPSM review Page 35 of 35
11. hicles that are registered and operated in specified salt belt states may exhibit corrosion damage to the front lower control arms e Inspect the front lower control arms for corrosion damage Measure the thickness of the front lower control arm steel If specified levels of corrosion damage have occurred as described in this bulletin replace the front lower control arms with new front lower control arms that incorporate additional holes in the upper and lower panels If the front lower control arms do not require replacement add drainage holes and treat the front lower control arms with rust proofing material e Inspect the front subframes for corrosion damage As a precautionary measure and to improve drainage from the subframe add drainage holes and treat the front subframe with rust proofing material If corrosion perforation is found as described in this bulletin replace the front subframe Page 5 of 35 SUMMARY OF SERVICE PROCEDURE e FRONT LOWER CONTROL ARMS Vehide in Yeni cation of affected WIM webhide Out Both RH amp LH VWisual ly inspect the tront front lower amns corer arms for replacement corrosion perforation Comos on YES perforation on either of RH and LH er E HO 1 5tor Balow 1 5 more HO Possible to i inert on either VES of i Drill 2 x 12mm Thickness 5 diameter holes measurement 1 e SUBFRAME ASSEMBLY Verde In Veriticaton of affected WIH Wisual
12. ill Drill bit mm Center pointed type diameter Drill bit 12mm Center pointed type diameter Page 9 of 35 For removing burrs from around the drilled holes Straight nozzle type NOTE Additional drill bits should be obtained from your local Parts Supply vendor when needed TOOL KIT supplied to dealers by HMA Re Rane ip p Hole saw 40mm diameter Hole saw 20mm diameter Provided in tool kit Usage tips 1 Remove plug ejection spring from arbor 2 Use anti seize com pound on arbor threads when replacing hole saw 3 Spin hole saw cutter before contacting cut ting surface to minimize tooth damage With center point Usage tips 1 Remove plug ejection spring from arbor 2 Use anti seize com pound on arbor threads when replacing hole saw 3 Spin hole saw cutter before contacting cut ting surface to minimize tooth damage Page 10 of 35 eK ip Bulletin Number 09 01 022 90 degree angle nozzle type provided in tool kit Thickness gauge Measuring thickness of panel Flexible magnet Flexible type provided in tool kit Control arm drill 2 templates provided ing template Each can be used on either left or right control arm NOTE Dealers will automatically be supplied with a Tool Kit from HMA NOTE Additional hole saws and arbors should be obtained by calling SPX at 800 345 2233 Please note the replacement hole saws from SPX are compatible with the a
13. lyinspect the tront subframe for comroasdon perforation Carefully inspect indudimng loser arm adjoining areas Corrosion Perforation Verde Out Subfra me replace ment NO Apply cavity wer Page 6 of 35 A HYUNDAI Technical Service Bulletin APPLICABLE VEHICLES VERIFY THAT THE VEHICLE IS IDENTIFIED AS AFFECTED BY THE CAMPAIGN VIA WEBDCS Models 2001 2003 XD Elantra 2003 GK Tiburon Applicable vehicle production date range e XD Elantra From Job 1 through January 13 2003 e GK Tiburon From Job 1 through January 13 2003 Area Salt belt states Connecticut Delaware Illinois Indiana lowa Maine Maryland Massachusetts Michigan Minnesota Missouri New Hampshire New Jersey New York Ohio Pennsylvania Rhode Island Vermont West Virginia Wisconsin and the District of Columbia PARTS KIT REQUIRED FRONT LOWER CONTROL ARMS tera a 54505 2D002QQH Nut 2EA Bolt 2EA Bolt 4EA A bush mounting G bush mounting ee S Page 7 of 35 A A bush mounting bolt B G bush mounting bolt SUBFRAME ASSEMBLY 62405 2D011QQH Subframe 2 nuts 2 bolts OO 62405 2C511QQH Subframe 2 nuts 2 bolts rrr WAX APPLICATION FOR CORROSION PREVENTION XD GK 62460 2D000QQH 2 Rubber plugs For plugging 40mm holes after wax application Page 8 of 35 cant Bulletin TOOLS REQUIRED not supplied in tool kit Dealer supplied No Name o Image T Hammer Electric dr
14. n to leave your vehicle at your Hyundai dealer to have this service performed Repair times will vary and depend on your dealer s appointment schedule What should you do We urge you to call your Hyundai dealer to schedule an appointment to have this work per formed as soon as possible What if you have other questions If you have any difficulty having this repair performed we recommend that you call the Hyun dai Customer Assistance Center at 1 800 633 5151 If you are still not satisfied that we have remedied this situation without charge and within a reasonable amount of time you may wish to write to the Administrator National Highway Traffic Safety Administration 1200 New Jer sey Avenue SE Washington D C 20590 or call their toll free Vehicle Safety Hotline at 1 888 327 4236 TTY 1 800 424 9153 or go to http www safercar gov Reimbursement Notification Hyundai has a program for reimbursing owners of 2001 through 2003 Elantras and 2003 Tibu rons produced through January 13 2003 who paid to have the front lower control arms replaced after April 14 2008 and prior to receiving this recall notification letter To obtain information about reimbursement from Hyundai please call the Hyundai Customer Assistance Center at 1 800 633 5151 Ask about reimbursement information for campaign 091 We urge your prompt attention to this important safety matter Hyundai Motor America Page 2 of 35 July 10 2009 TO ALL HYUND
15. ower control arm 7 Repeat this procedure for the right lower control arm Drll bit 8 With a file remove burrs around the holes Totally remove remnants of rust around the holes CAUTION If the burrs are not fully removed it may prevent the thickness gauge from being inserted over the edge of the drilled holes 9 Inspect the thickness of the front lower control arm lower panels with the 1 5mm groove of the thickness gauge G Check the thickness of the front lower control arms at as many points around the hole as possible Page 30 of 35 7 HYUNDAI Technical Service Bulletin 10 If either the right or left front lower control arm metal fits into the thickness gauge or is inserted into the groove replace both right and left assemblies If the front lower control arm metal does not fit into the 1 5mm thickness gauge go to the procedure FRONT LOWER CONTROL ARM WAX APPLICATION FOR CORROSION PREVENTION e FRONT LOWER CONTROL ARM WAX APPLICATION FOR CORROSION PREVENTION 1 Align the right angled triangle template with the 2 current holes H in the center of the front lower control arm as shown in the photo at the right Put a mark I on the right front lower control arm Repeat this procedure for the left Page 31 of 35 2 Center the 20mm hole saw on the mark and drill a hole in the right lower control arm Repeat this procedure for the left 70mm hole sayy Page 32 of 35
16. rbors in the supplied tool kit Page 11 of 35 J 50236 1 5 8 40mm Hole Saw J 50237 1 2 Hex Shank Arbor J 50238 13 16 20mm Hole Saw J 50239 3 8 Hex Shank Arbor CHEMICAL KIT 1 Wax injection gun P N 00232 19036 2 Cavity wax P N 00232 19034 1 vehicle per can VALHIGARD cra a SIONAL f y pr RUST PREVENTIVE Page 12 of 35 C Bulletin Undercoating P N 00232 19035 Spray Black color 10 vehicles per can NOTE Dealers will be supplied with an initial order of the Chemical Kit Additional product should be ordered through your facing PDC SERVICE PROCEDURE e SUBFRAME INSPECTION 1 Lift up the vehicle Page 13 of 35 2 Lightly strike the subframe thorougly with a hammer CAUTION Be careful DO NOT strike the subframe too hard to prevent deformation damage 3 Inspect the subframe for corrosion perforation The photo at the right shows corrosion perforation CAUTION Make sure to inspect for corrosion perforation throughout the subframe including the sides NOTE If there is any corrosion perforation replace the subframe assembly following the SUBFRAME REPLACEMENT PROCEDURE If no perforation exists go to the SUBFRAME WAX APPLICATION FOR CORROSION PREVENTION procedure e SUBFRAME WAX APPLICATION FOR CORROSION PREVENTION 1 Put a marking point C on the left side member as indicated in the photo below Page 14 of 35 A HYUNDAI Technical
17. roughly with a hammer to loosen internal rust b Insert a flexible magnet through the 40mm and 20mm holes and remove fragments of rust py HYUNDAI Technical Service a Bulletin Group CAMPAIGN Number 99 91 0922 Page 19 of 35 c Insert the air gun into the inside of the subframe through holes in the right and left side members and blow out rust from inside the subframe d Air guns required e Repeat steps from a to c 2 or more times Page 20 of 35 2 Bulletin 13 Pour about 850cc of cavity wax into the injection gun reservoir Spray cavity wax into the inside of the subframe through all the holes until wax drains through the holes NOTE Make sure to use one bottle 1000cc of cavity wax per vehicle for the subframe and front lower control arm Use about 150cc cavity wax for front lower control arm wax application CAUTION 1 Protect yourself by wearing goggles a respirator gloves etc CAUTION 2 Insure proper ventilation of your working area CAUTION 3 Be careful NOT to contaminate nearby parts and panels with wax or undercoating 14 Spray undercoating on the subframe especially around the holes Page 21 of 35 15 Cover both 40mm holes with hole plugs Page 22 of 35 ee Bulletin Number 09 01 022 This instruction provides a procedure to replace the ELANTRA XD and TIBURON GK subframe more easily and efficiently than the original procedure e SU
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