High Pressure Fuel Pipe Inspection And Replacement (Recall 207) – 2021-2022 Hyundai Santa Fe & Sonata

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Technical Service Bulletin
GROUP NUMBER
RECALL 21-01-055H-2
DATE MODEL(S)
July, 2021 Santa Fe (TMa)
Sonata (DN8a)
SUBJECT: HIGH PRESSURE FUEL PIPE INSPECTION
AND REPLACEMENT (RECALL 207)
This TSB supersedes TSB# 21-01-055H-1 to revise the high-pressure fuel pump flange
nut torque specification listed in pages 5, 8, and 9.
Description: On certain 2021-2022MY Santa Fe (TMa) and Sonata (DN8a) vehicles equipped
with 2.5T GDI engines, the fuel pipe connecting the high-pressure fuel pump to the fuel rail may
have been installed with insufficient torque during assembly. Additionally, certain fuel pipes could
have been produced outside of Hyundai’s specification for concentricity. A fuel pipe that has been
installed with insufficient torque or improper concentricity could allow fuel to leak at its connections
increasing the risk of an engine compartment fire. Follow the procedure outlined in this TSB to
inspect, tighten and/or replace, the fuel pipe as needed.
Applicable Vehicles:
Certain 2021-2022MY Santa Fe (TMa) vehicles equipped with 2.5T GDI engines.
Certain 2021-2022MY Sonata (DN8a) vehicles equipped with 2.5T GDI engines.
Parts Information:
PART NAME
PART NUMBER
FIGURE NOTES
OLD NEW
High
Pressure
Fuel Pipe
35305-2S000 35305-
2S200QQH
Replace if it does not
pass LOT code
inspection, or if a leak
is found after
As required by federal law, dealer must not deliver new vehicle for sale or for lease to
customers until all open recalls have been performed. Dealers should also perform all open
recalls on used vehicles, demo, and rental vehicles prior to placing them into customer use
and whenever an affected vehicle is in the shop for any maintenance or repair.
When a vehicle arrives at the Service Department, access Hyundai Motor America’s
“Warranty Vehicle Information screen (VIS)” WEBDCS to identify open Campaigns.
 IMPORTANT
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 2 of 9
SUBJECT:
SUBJECT:
Test Oil
Paper SP045-07305
1 box contains 100 test
paper strips
The oil test paper is the
same as the one currently in
use for active HMA Recalls
180 and 189. Your
dealership may already have
some on-hand. Please
confirm before ordering
additional.
Additional oil test paper can
be ordered through BOSCH
at 1-866-539-4248.
Special Service Tool Information:
DESCTRIPTION PART NUMBER FIGURE NOTE
3/8” Drive 12-Point Metric 19
mm Deep Flank Drive® Flare
Nut Crowfoot Wrench –
ANM19(or equivalent)
09314-3Q100
For removal and
installation of the high
pressure fuel pipe nut.
NOTE: This is an essential tool that was previously shipped to all active dealers. Additional units
can be ordered through Bosch at 1-866-539-4248.
Warranty Information:
MODEL OP CODE OPERATION OP
TIME
CAUSAL
PART
NATURE
CODE
CAUSE
CODE
Santa Fe
(TMa)
Sonata
(DN8a)
11DA24R0
HIGH PRESSURE PIPE LOT
INSPECTION (OK) + LEAK
INSPECTION (OK)
0.4 35305-
2S200QQH B11 ZZ7
11DA24R1 LOT INSPECTION (NG) + HIGH
PRESSURE PIPE REPLACEMENT 0.9 35305-
2S200QQH A31 ZZ4
11DA24R2
LOT INSPECTION (OK) + LEAK
INSPECTION (NG) + HIGH
PRESSURE PIPE REPLACEMENT
1.3 35305-
2S200QQH B11 ZZ7
NOTE 1: Submit Claim on Campaign Claim Entry Screen.
NOTE 2: If a part that is not covered by this recall is in need of replacement while performing this
recall, and the affected part is still under warranty, please submit a separate claim using the same
repair order. If the affected part is out of warranty, submit a prior approval request for goodwill
consideration prior to performing the work.
NOTE 3: One (1) oil test paper strip will be reimbursed via sublet for labor op codes 11DA24R0 &
11DA24R1. Two (2) oil test paper strips will be reimbursed via sublet for labor op code
11DA24R2.
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 3 of 9
SUBJECT:
SUBJECT:
Inspection Procedure:
1. Open the hood and remove the engine top cover (A).
2. Locate the high pressure fuel pipe and pipe insulator
(as shown by the red arrow).
3. On the high-pressure fuel pipe insulator, locate the printed LOT number.
A
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 4 of 9
SUBJECT:
SUBJECT:
4. Review the LOT number inspection criteria below for the high pressure fuel pipe.
 If the LOT number is 210111, it is NG.
o Take a picture of the LOT number and replace the high-pressure fuel pipe with the
Service Procedure on page 8.
 If the LOT number is not 210111, it is OK.
o Take a picture of the LOT number proceed to step 5 in the Inspection Procedure.
Using STUI, take clear picture(s) of the Lot Number.
Please include the VIN or copy of the RO with the VIN in the STUI picture of the fuel pipe.
5. Remove the high-pressure fuel pump foam
cover (B).
For a guide on how to capture pictures and videos using STUI, refer to the Hyundai
Tech Info website and select:
Diagnostic Tools > GDSM and STUI Tips > Tip #622 “Capturing Video and
Photos for Techline and PA using the STUI Camera”
NOTICE
B
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 5 of 9
SUBJECT:
SUBJECT:
6. Remove the air intake hose (C) and the air
cleaner assembly (D).
7. Using a torque wrench and SST 09314-3Q100,
verify that the high-pressure fuel pump flange
nut (E) is torqued to specification.
8. Using a torque wrench and SST 09314-3Q100,
verify that the high-pressure fuel rail flange
nut (F) is torqued to specification.
Tightening Torque:
 25 lb-ft (34 Nm)
NOTICE
Tightening Torque:
 25 lb-ft (34 Nm)
NOTICE
E
F
C
D
Tightening Torque:
 Intake hose clamp:
o 2.9 lb-ft (3.9 Nm)
 Air cleaner mounting bolt:
o 6.5 lb-ft (8.8 Nm)
NOTICE
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 6 of 9
SUBJECT:
SUBJECT:
9. Reinstall the air intake hose (C) and the air
cleaner assembly (D).
10. Turn the ignition switch ON and start the engine.
Step on the accelerator pedal until engine
reaches 5000 RPM.
Repeat 2-3 times, building fuel pressure in the
high pressure fuel pipe to expose leaks.
11. Turn the ignition switch OFF and disconnect the
RCV hose (G) to begin air cleaner removal.
Removing the air cleaner is necessary to
properly inspect for leaks using the oil test
paper.
12. Disconnect the air intake hose (C).
If extra working room is needed, remove the air
cleaner assembly (D).
G
C
D
C
D
Tightening Torque:
 Intake hose clamp:
o 2.9 lb-ft (3.9 Nm)
 Air cleaner mounting bolt:
o 6.5 lb-ft (8.8 Nm)
NOTICE
Tightening Torque:
 Intake hose clamp:
o 2.9 lb-ft (3.9 Nm)
 Air cleaner mounting bolt:
o 6.5 lb-ft (8.8 Nm)
NOTICE
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 7 of 9
SUBJECT:
SUBJECT:
13. Inspect before and after the high pressure fuel pump flange for leakage using an oil test paper.
14. Inspect before and after the high pressure fuel rail flange for leakage. Use the other side of
the oil test paper if necessary.
15. If no leak is found, reinstall parts in reverse order
of disassembly. Removal and replacement are
not necessary.
16. If fuel leak is found, replace high pressure fuel
pipe with the following service procedure below.
After pipe inspection, if there is a
sufficiently dry area on the previously
used test oil paper, use it again for
reinspection. Otherwise, use a new
test oil paper strip.
NOTICE
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 8 of 9
SUBJECT:
SUBJECT:
Fuel Pipe Replacement Service Procedure:
1. Deplete the residual fuel pressure in the fuel lines following the procedure outlined in the Shop
Manual section.
Refer to the shop manual section for complete service procedure:
Engine Control / Fuel System > Fuel Delivery System > Release Residual Pressure in Fuel Line
2. Turn the ignition switch OFF and disconnect the battery (-) terminal.
3. If not already removed, disconnect the air
intake hose (C).
If extra working room is needed, remove the
air cleaner assembly (D).
4. Remove the high pressure pipe bracket bolts
(H) and fuel pump flange nut (E).
Remove high pressure fuel pump flange nut
with SST 09314-3Q100.
Be sure to wrap the connection joints with a shop towel to capture any dripping fuel.
NOTICE
Be sure to record the radio presets prior to battery disconnection.
NOTICE
Tightening Torque:
 Intake hose clamp:
o 2.9 lb-ft (3.9 Nm)
 Air cleaner mounting bolt:
o 6.5 lb-ft (8.8 Nm)
NOTICE
C
D
Tightening Torque:
 High pressure pipe bracket bolts:
o 7.95 lb-ft (10.8 Nm)
 High pressure pump flange nut:
o 25 lb-ft (34 Nm)
NOTICE
H
E
HIGH PRESSURE FUEL PIPE INSPECTION AND REPLACEMENT (RECALL 207)
TSB #: 21-01-055H-2 Page 9 of 9
SUBJECT:
SUBJECT:
5. Remove the high pressure fuel rail flange nut
(F) with SST 09314-3Q100.
6. Remove the damaged high pressure fuel pipe.
7. Install the new pipe and reinstall the removed parts in reverse order of removal and
reconnect the negative battery terminal.
8. After installing the new high pressure fuel pipe, proceed to Inspection Procedure steps 10-16
to verify that the leak issue has been resolved.
9. The service procedure is now complete.
Tightening Torque:
 25 lb-ft (34 Nm)
NOTICE F
Reprogram the radio presets from Service Procedure Step 2.
NOTICE
After pipe inspection, if there is a sufficiently dry area on the previously used
test oil paper, use it again for reinspection. Otherwise, use a new test oil
paper strip.
NOTICE
*******************************************************************************************************
This notice applies to your Hyundai, VIN:
Dear
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Hyundai has decided that a defect which
relates to motor vehicle safety exists in your vehicle, with the VIN shown above. As part of its continued investigation, Hyundai is expanding
recall campaign 206, a safety recall to repair a fuel pipe in certain model year 2021 Hyundai Santa Fe vehicles equipped with 2.5-litre
Turbo engines and produced for sale in the U.S. market. The expansion adds additional 2021 – 2022 Hyundai Santa Fe and 2021 – 2022
Hyundai Sonata vehicles equipped with 2.5-litre Turbo engines produced by HMMA for sale in the U.S. and Canadian markets to the
recall population.
What is the problem?
The fuel pipe connecting the high-pressure fuel pump to the fuel rail may have been insufficiently tightened during assembly. Additionally,
certain fuel pipes could have been produced outside of Hyundai’s specification for concentricity. A fuel pipe that has been installed with
insufficient tightness or improper concentricity could allow fuel to leak at its connections, increasing the risk of an engine compartment
fire.
What will Hyundai do?
Your Hyundai dealer will confirm the fuel pipe’s production lot date code. Fuel pipes confirmed to be from the affected lot will be replaced
and tightened to the proper torque setting. Fuel pipes not originating from the affected lot will be inspected for fuel leaks. If a leak is found,
the fuel pipe will be replaced and tightened to the proper torque setting. If no fuel leak is found, the fuel pipe will be tightened to the proper
torque setting. This procedure will be performed at NO CHARGE to you.
What should you do?
Please contact your nearest Hyundai dealer to schedule the recall repair as soon as possible.
If the Malfunction Indicator Light is illuminated in your vehicle, you should seek service at your Hyundai dealer as soon as possible. The
actual time required to perform the repair will take approximately one hour or less, however your vehicle may be needed longer. Therefore,
we recommend scheduling a service appointment to minimize inconvenience.
If you have other questions
If you require further assistance, you may contact the Hyundai Customer Care Center at 1-855-371-9460. If you believe that the dealer or
Hyundai has failed or is unable to remedy the defect within a reasonable time, you may submit a complaint to the Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Avenue S.E., Washington, D.C. 20590, or call the toll free Vehicle Safety Hot Line
at 1-888-327-4236 (TTY: 1-800-424-9153), or go to https://www.safercar.gov.
Thank you for your attention to this important safety matter. We apologize for any inconvenience this may have caused you.
Hyundai Motor America
Hyundai Motor America
P.O. Box 20839
Fountain Valley, CA 92728-9937
IMPORTANT SAFETY RECALL
2021 – 2022 Santa Fe and 2021 – 2022 Sonata
Fuel Pipe
Importante Retiro del Mercado por Motivos de Seguridad — Si tiene preguntas llama 1-800-633-5151 y oprima “8”
NHTSA Recall Number: 21V-524
Hyundai Recall Number: 207
This is an important Safety Recall.
• Please contact your nearest Hyundai dealer to schedule the repair as soon as possible.
• This repair will be performed at NO CHARGE to you.
• To locate your nearest Hyundai dealer and schedule your appointment please visit:
www.HyundaiUSA.com/Campaign207

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