Service Procedure

NOTICE:
IT IS EXPECTED THAT LESS THAN 1% OF THE VEHICLES INVOLVED IN THIS CAMPAIGN WILL EXPERIENCE THE CONDITIONED DESCRIBED.

A INSPECTION

CAUTION:
GASOLINE OR GASOLINE VAPORS ARE HIGHLY FLAMMABLE. IF AN IGNITION SOURCE IS PRESENT A FIRE COULD OCCUR. HAVE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEARBY.
1. Disconnect the negative battery cable.
2. Remove fuel tank filler cap to relieve any fuel vapor pressure.
3. Reinstall fuel tank filler cap and lighten until an audible "click" is heard.
4. Remove fuel vapor canister purge line from canister fining marked "TANK".
5. Disconnect radiator pressure test cap from Radiator Pressure Test Pump - Kent Moore J 24460-01 or equivalent.
6. Insert threaded end of Radiator Pressure Tester Hose into fuel tank vapor purge line.


7. Pressurize the fuel tank and emissions system with 30 strokes of the Radiator Pressure Tester Hand Pump. The pressure gauge on pump will indicate a low amount of pressure. Note the location ot the needle in relationship to the gauge and monitor for one minute. If the emissions system, fuel tank filler cap and fuel tank sender seal ring are correctly installed there should be no loss of pressure.

NOTICE:
DO NOT UNDER ANY CIRCUMSTANCE, USE SHOP AIR HOSE IN PLACE OF RADIATOR PRESSURE TESTER HAND PUMP OVER PRESSURIZING OF THE FUEL TANK OR EMISSIONS SYSTEM COULD LEAD TO SYSTEM LEAKAGE OR DAMAGE. IF AN IGNITION SOURCE IS PRESENT, A FIRE COULD OCCUR.

8. After one minute, slowly remove fuel tank cap while listening for pressure being released past the filler cap threads.

If release of pressure is evident the seal ring has not been displaced. Go to Step
9. Stop at Step 12.

It no pressure is detected when fuel tank filler cap is removed it will be necessary to remove fuel tank to replace fuel tank sender seal ring. Proceed to Procedure B.

9. Disconnect Radiator Pressure Tester Hand Pump hose from fuel tank purge hose.
10. Reconnect fuel tank purge hose to fuel vapor canister.
11. Reconnect negative battery cable.
12. Install Campaign Identification Label.

B. REPLACEMENT OF FUEL SENDER SEAL RING

CAUTION:
GASOLINE OR GASOLINE VAPORS ARE HIGHLY FLAMMABLE. IF AN IGNITION SOURCE IS PRESENT A FIRE COULD OCCUR. HAVE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEARBY.

1. Drain fuel from tank.

CAUTION:
NEVER DRAIN OR SMRE GASOLINE IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF FIRE OR EXPLOSION.

2. Raise vehicle on hoist.

3. Remove fuel tank plastic shield.





4. Support fuel tank and remove brackets. (Figure 1)

5. Disconnect fuel tank filler neck.
6. Disconnect fuel lines at filler neck.
7. Lower tank and disconnect fuel lines and electrical connections at sender.





8. Remove fuel sender and seal ring using tool J 36608 or J 24187 (Figure 2).
9. Replace seal P/N 3893116 and reinstall sender using tool J 36608 or J 24187.
10. Raise tank and reconnect fuel lines and electrical connections at sender.
11. Reconnect fuel lines at filler neck.
12. Reconnect fuel tank filler neck.

13. Reinstall fuel tank brackets and tighten bracket bolts to 45 N-m (33 lb.ft.).
14. Install fuel tank plastic shield.
15. Reinstall fuel.

16. Reinstall fuel tank filler cap.

17. Remove tester from purge line.
18. Reinstall purge line to vapor canister.
19. Reinstall negative battery cable.
20. Install Campaign Identification Label.