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Refuel Vapor Control Valve (TS 03 03082R)

Publication date: 2002-03-08
Reference number: TS 03 03082R

REFUEL VAPOR CONTROL VALVE

REFUEL VAPOR CONTROL VALVE

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 03 03082R, Date of Issue:  March 08, 2002
SUZUKI: 2001-2002 ESTEEM
SECTION: Engine

AFFECTED VIN(S):

ALL 2001 1.8L SEDANS & WAGONS 

2002 1.8L SEDANS AND WAGONS WITH VINS BETWEEN: 

- JS2GB41S_25400001 - JS2GB41S_25404574 (SEDAN) 

- JS2GB41W_25400001 - JS2GB41W_25402619 (WAGON) 

BULLETIN REVISION NOTE: 

The "AFFECTED VIN(S)", "Category", and "PART(S) INFORMATION" sections have been revised. 

CONDITION:

These vehicles may have damage to the refuel vapor control valve due to interference with the body panel. If the refuel vapor control valve is damaged, the Malfunction Indicator Lamp (MIL) will illuminate.

CAUSE:

In certain cases, the refuel vapor control valve may come into contact with the underside of floor panel, just above the fuel tank. This may cause damage to the refuel vapor control valve. A damaged refuel vapor control valve will allow fuel vapors to enter the atmosphere.

CORRECTION:

Inspect the gap between the fuel tank and the underside of the floor panel, and if necessary, replace the refuel vapor control valve.

PART(S) INFORMATION:

PART(S) INFORMATION

PART NUMBER DESCRIPTION QTY. NOTES
89491-65G60 Refuel Vapor Control Valve 1 Replace as required.
  1. VEHICLE INSPECTION PROCEDURE 

    Using the vehicle VIN, perform a CLAIM HISTORY INQUIRY and inspect for a DG STICKER on the vehicle (Fig 1 ).

    • If the CLAIM HISTORY INQUIRY states DG NOT YET PERFORMED and a DG STICKER is not present, proceed to "B. REPAIR PROCEDURE."
    • If the CLAIM HISTORY INQUIRY states DG NOT YET PERFORMED and a DG STICKER is present, contact ASMC Warranty Department (800) 568- 9968. They will update vehicle claim history.
    • If the CLAIM HISTORY INQUIRY states DG ALREADY PERFORMED and a DG STICKER is present, return the vehicle to the customer or dealer inventory. No further action is needed.
    • If the CLAIM HISTORY INQUIRY states DG ALREADY PERFORMED and a DG STICKER is NOT present, proceed to " D . CAMPAIGN STICKER INSTALLATION PROCEDURE."
    Fig 1: Inspecting DG Sticker
    G03366435
  2. FUEL TANK MEASUREMENT PROCEDURE 
    1. Hoist vehicle.
    2. Locate the measuring gauge enclosed with this bulletin and identify the end of the measuring gauge stamped "01,02MY". This end of the gauge is 15mm high (Fig 2 ).
      NOTE: Additional gauges are available via ASMC's Parts Department.
      Fig 2: Identifying Measuring Gauge
      G03366436
    3. Refer to Fig 3 for the measuring location under the vehicle.
      Fig 3: Identifying Measuring Location
      G03366437

    Using the 15mm end of the gauge, measure and note the clearance between the fuel tank flange and the underside of the floor panel as shown in Fig 4 .

    • If the clearance is more than 15mm, return the vehicle to the customer or dealer inventory. No further action is needed. Proceed to "D. CAMPAIGN STICKER INSTALLATION PROCEDURE."
    • If the clearance is less than 15mm, the vehicle's fuel tank needs to be removed, the refuel vapor control valve replaced, the valve's hose clamp tabs adjusted, and the fuel tank reinstalled with more than 15mm of fuel tank flange clearance. Proceed to "C. REPAIR PROCEDURE."
    Fig 4: Measuring Clearance Between Fuel Tank Flange And Underside Of Floor Panel
    G03366438
  3. REPAIR PROCEDURE 
    1. Release vehicle fuel pressure using the following procedure:
      CAUTION: Make sure that the engine is cold before releasing the fuel pressure. Damage to the catalyst may occur if this procedure is done when the engine is hot.
      1. Place the transmission gear shift in Neutral (M/T) or Park (A/T), set the parking brake and block the drive wheels.
      2. Remove the fuel filler cap to release fuel vapor pressure in the fuel tank. Reinstall the fuel filler cap.
      3. Remove the relay box cover and remove the fuel pump relay (Fig 5 ).
        4. Fig 5: Removing Fuel Pump Relay
        G03366439
      4. Start the engine and run it until it stops for lack of fuel. Repeat cranking 2 or 3 times for about 3 seconds each time to dissipate fuel pressure in the lines. Fuel connections are now safe for servicing.
    2. Disconnect negative cable from battery.
    3. Remove rear seat cushion, rear seat back, right side sill scuff, right front partition trim and right rear door opening trim.
    4. Disconnect connectors from fuel tank wire harness (Fig 6 ).
      5. Fig 6: Disconnecting Connectors From Fuel Tank Wire Harness
      G03366440
    5. Hoist vehicle.
    6. Remove muffler (Fig 7 ).
      WARNING: To avoid danger of being burned, do not touch the exhaust system when the system is hot. Any service on the exhaust system should be performed when the system has cooled down.
      Fig 7: Removing Muffler
      G03366441
    7. Disconnect connectors from EVAP canister air valve. Be sure to remove all debris around the quick connectors with compressed air before disconnecting. To disconnect the quick connectors, push both sides of joint in while pulling hose joint out (Fig 8 ).
      Fig 8: Disconnecting Connectors From EVAP Canister Air Valve
      G03366442
    8. Disconnect fuel filler hose and breather hose from filler neck (Fig 9 ).
    9. Use a hand operated pump to pump fuel out through the fuel tank filler.
      WARNING:
      • Never drain or store fuel into an open container to avoid the possibility of fire or explosion.
      Fig 9: Disconnecting Fuel Filler Hose And Breather Hose From Filler Neck
      G03366443
      CAUTION: Do not force hose from hand operated pump into or out of fuel tank. Doing so may damage inlet valve.
    10. Remove all debris around the quick connectors with compressed air. Disconnect fuel pipe joints from pipes. To disconnect the quick connectors, locate the special tool enclosed with this bulletin and insert it between joint and pipe (Fig 10 ).
      Fig 10: Inserting Special Tool Between Joint And Pipe
      G03366444

      SPECIAL TOOL: 

      09919-47020 

      NOTE: Additional Special Tools are available via ASMC's Parts Department.
      WARNING: A small amount of fuel may be released after the fuel hose is disconnected. To reduce the chance of personal injury, cover hose and pipe to be disconnected with a shop cloth. Be sure to place the cloth in an approved container when the disconnection has been completed.
    11. Support the fuel tank with a jack and remove the fuel tank from the vehicle.
    12. Remove all debris around the refuel vapor control valve quick connectors with compressed air. Disconnect the hoses from the refuel vapor control valve. To disconnect the quick connectors, push both sides of joint in while pulling hose joint out.
    13. Remove the refuel vapor control valve screws with a hand impact driver and remove the refuel vapor control valve from the fuel tank.
    14. Clean the mating surfaces of the refuel vapor control valve and fuel tank. Install the new refuel vapor control valve (89491-65G60) to the fuel tank.
      CAUTION: Align screw holes in fuel tank gasket and plate accurately or vapor may leak (Fig 11 ).
      Fig 11: Aligning Screw Holes In Fuel Tank Gasket
      G03366445
    15. Connect the hoses to the refuel vapor control valve and clamp the hoses with the hose clamp tabs facing downward (Fig 12 ).
      Fig 12: Connecting Hoses To Refuel Vapor Control Valve
      G03366446
      CAUTION: Be sure hose clamp tabs face downward.
    16. Install the fuel tank to the vehicle. Tighten the fuel tank fixer belt bolts (Fig 13 ).

      Tightening torque: 

      1. 50 N.m (5.0 kg-m, 36.5 lb-ft) 
      CAUTION: Make sure that the fuel tank flange is not positioned between the body and fuel tank fixer belt (Fig 14 ).
      Fig 13: Checking Fuel Tank Flange Position
      G03366447
    17. Measure the clearance between the fuel tank flange and the underside of the floor panel using the end of the measuring gauge stamped "01,02MY". The end of the gauge stamped "01,02MY" is 15mm high.
      • If the clearance is less than 15mm, re-adjust the tank by loosing the fuel tank fixer belt bolts, push the tank rearward while first tightening the rear fuel tank fixer belt bolts and then tightening the front bolts. (Fig 14 ).
      Fig 14: Measuring Clearance Between Fuel Tank Flange And Underside Of Floor Panel
      G03366448
    18. Connect the fuel filler hose and the breather hose to the filler (Fig 15 ). Tighten clamps.

      Tightening torque: 

      1. 3.5 N.m (0.35 kg-m, 2.5 lb-ft) 
      Fig 15: Connecting Fuel Filler Hose And Breather Hose To Filler
      G03366449
    19. Connect the pipe joints to each pipe (Fig 16 ).
      CAUTION: When connecting joint, clean outside surfaces of pipe, push joint into pipe until joint lock clicks and check to ensure that pipes are connected securely, or a fuel leak may occur.
      Fig 16: Connecting Pipe Joints To Pipes
      G03366450
    20. Connect the EVAP canister air valve connectors. Connect vapor control valve hose and purge hose to EVAP canister. For the quick connector, push joint into pipe until joint lock clicks (Fig 17 ).
      Fig 17: Connecting EVAP Canister Air Valve Connectors
      G03366451
    21. Install the muffler and tighten the muffler nuts (Fig 18 ).
      Fig 18: Installing Muffler
      G03366452
    22. Connect connectors from fuel tank wire harness (Fig 19 ).
      23. Fig 19: Connecting Connectors From Fuel Tank Wire Harness
      G03366453
    23. Install rear seat cushion, rear seat back, right side sill scuff, right front partition trim and right rear door opening trim.
    24. Refuel fuel tank with fuel removed during STEP 9.
    25. Re-install the fuel pump relay to the relay box. Reinstall the relay box cover (Fig 20 ).
      26. Fig 20: Re-Installing Fuel Pump Relay To Relay Box
      G03366454
    26. Connect the negative battery cable.
    27. With engine OFF and ignition switch ON, check for fuel leaks.
    28. Start the engine and check each joint of the exhaust system for leakage.
    29. Road test the vehicle and confirm that there are no service related defects.
  4. CAMPAIGN STICKER INSTALLATION PROCEDURE 

    Enter your dealer number on the DG Recall Campaign sticker and install it to the flat surface on the upper radiator support, just above the left head lamp (Fig 1 ). This will identify that the campaign has been completed.

    IMPORTANT NOTICE FOR CALIFORNIA DEALERS: 

    The California Air Resources Board requires that all applicable emission recall campaigns to be completed prior to California registration renewal. If the owner does not have this recall performed, they will not be able to renew their California vehicle registration. 

    After completing the recall service, your Service Department must give each owner a "Proof of Correction Certificate." If required, the owner must present this certificate to the Department of Motor Vehicles when renewing their California registration. Refer to ATTACHMENT B of the Campaign Service Bulletin SC-18. ASMC will be supplying a quantity of these certificates to each California Suzuki Dealer. Be sure to complete this certificate after repairs have been completed and attach it to the customer's copy of the completed repair order. 

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