D. Repair Procedure
(Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)CAUTION:
^ The following Repair Procedure must be performed in a well ventilated area, away from direct sunlight, flames, or sparks.
^ Gasoline is very flammable, use extreme caution when working near or around gasoline.
^ Appropriate hand and eye protection must be worn when working with gasoline.
1. Drain all of the fuel from the fuel tank.
NOTE:
keep a note of how much fuel is drained, it will need to be returned to the tank later.
2. Lift the vehicle on the host.
CAUTION:
Make certain the exhaust system is cool before proceeding to the following steps.
3. Using a large flat head screwdriver, remove the two (2) front rubber exhaust hangers from the exhaust system.
4. Remove the two (2) rear rubber exhaust hangers from the exhaust system.
5. Remove the center rubber exhaust hanger.
6. Loosen the two (2) front exhaust nuts at the converter.
7. While an assistant is holding the rear exhaust pipes, hold the exhaust pipe (at the converter) with one hand and remove the (2) exhaust nuts.
8. Remove the complete exhaust system from the vehicle.
9. Position a transmission jack under the center of the fuel tank and raise it until the jack contacts the tank.
CAUTION:
To protect the fuel tank from damage, place padding between the jack and the fuel tank.
10. Remove the two (2) rearward fuel tank strap bolts.
11. Gently bend the fuel tank straps downward.
NOTE:
Do not over bend the straps.
12. Slowly lower the fuel tank down approx. 6".
13. Loosen the worm clamp and remove the large fuel inlet hose.
NOTE:
^ Prior to removing the hose, make a reference mark on the hose to insure proper position during reinstallation.
^ It is not necessary to remove the other end of the hose.
14. Remove the inbound hose from the charcoal canister side.
NOTE:
^ Prior to removing the hose, make a reference mark on the hose to insure proper position during reinstallation.
^ It is not necessary to remove the other end of the hose.
15. Lower and remove the fuel tank.
16. Mount the SST (Fuel Pump Lock Ring Removal Wrench) onto the lock ring and turn the SST in a counterclockwise direction to remove the lock ring.
17. Discard the lock ring.
18. Remove the fuel pump by grasping the fuel pump housing and lifting upward.
CAUTION:
^ Some amount of fuel is inside of the fuel pump, while removing the fuel pump, pour the fuel back into the fuel tank being careful not to spill the fuel.
^ When lifting the fuel pump out of the fuel tank, make sure that the float is not damaged or bent.
19. Lay the fuel pump on a clean surface.
20. Remove and discard the fuel pump seal.
21. Remove the large fuel inlet hose from the removed fuel tank.
NOTE:
Prior to removing the hose, make a reference mark on the hose to insure proper position during reinstallation.
22. Remove the charcoal canister hose from the removed fuel tank.
NOTE:
Prior to removing the hose, make a reference mark on the hose to insure proper position during reinstallation.
23. Obtain the new fuel tank and make a note of the production date printed on the label. You will need this date in future steps.
NOTE:
^ The label is attached on the rear side of the fuel tank.
^ If there is no label on the fuel tank, note the production date stamping on the bottom of the tank.
24. Install the large inlet hose on the new fuel tank and torque to 1.1-2.0 Nm (9.73-17.7 in. lbf.).
25. Install the charcoal canister hose on the new fuel tank and tighten the clamp.
28. Dispose of the old fuel tank according to your state and/or local regulations.
27. Install the new fuel tank in the reverse order of removal.
28. Torque to the following torque specifications:
^ Large inlet fuel hose on the fuel filler side: 1.1-2.0 Nm (9.73-17.7 in. lbf.)
^ Two (2) fuel tank straps: 43.1-60.8 Nm (31.8-44.8 ft. lbf.)
^ Two (2) front exhaust nuts at the converter: 43.1-60.8 Nm (31.8-44.8 ft. lbf.)
29. Install a new fuel pump seal onto the fuel tank.
NOTE:
Make sure that the seal is installed "level" onto the fuel tank and that no portion of the seal is tucked inside the fuel tank. Use a mirror to aid in the inspection.
30. Obtain the fuel pump.
31. Locate the white molded arrow on top of the fuel pump.
32. Hold the fuel pump above the fuel tank opening and visually align the arrow on the fuel pump between the molded ribs on the fuel tank.
33. Tilt the fuel pump so that the float enters the fuel tank.
34. After the float enters the fuel tank, straighten up the fuel pump to an upward position and slowly insert the fuel pump into the fuel tank.
CAUTION:
Make sure that the fuel pump seal does not become "rolled" or damaged.
35. During the fuel pump installation, the fuel pump may have moved slightly. Ensure the white molded arrow on top of the fuel pump is centered between the molded ribs on the fuel tank. If not, grasp the top of the fuel pump and move it until the arrow is centered.
36. Obtain the SST (Fuel Pump Position Retainer).
NOTE:
Prior to using the SST for the first time, the securing bolt (M6) may be difficult to thread onto the SST by hand. If so, "clean" the threads by partially threading the bolt on by hand, then use a 10 mm wrench to further clean the threads.
37. Carefully lower the SST (Fuel Pump Position Retainer) onto the top of the fuel pump and insent the SST "leg" into the square shape slot.
NOTE:
^ The installation of the SST keeps the fuel pump from popping upward (the fuel pump is under spring pressure) and/or the fuel pump seal from moving when the lock ring is removed. Ignore the dates stamped on the top surface of the SST.
38. Secure the SST by inserting the bolt through the square shape slot, threading it onto the SST, then snug the bolt down.
39. Using a mirror and a flashlight, inspect the complete circumference of the fuel pump seal for a "rolled" seal condition.
NOTE:
The fuel pump seal is between the fuel pump and the top of the fuel tank.
^ If the seal is rolled, proceed to the next step.
^ If the seal is not rolled, proceed to Step 43
40. Grasp the fuel pump housing and lift it up approx. 2".
41. Using the tip of your finger, correct the rolled portion of the seal.
42. Reinstall the fuel pump and repeat Step 39.
43. Obtain a new lock ring and align the molded arrow on the lock ring with the machined line (Lock Ring Start) on the SST.
NOTE:
The arrow on the lock ring represents the starting thread.
44. Lower the lock ring straight down until the threads just contact the fuel tank threads. At this time the lock ring should be laying flat on the fuel tank threads.
45. Using both hands, push down on the lock ring and turn it clockwise approx. 1" until the threads engage, then release the lock ring. Push downward on the lock ring on the opposite side of the black molded arrow. A "click" noise should be heard just as the threads "catch". Once the threads catch, proceed to the next step.
46. Install the SST onto the lock ring and tighten in a clockwise direction for 3/4 of a turn.
NOTE:
^ When the lock ring is being tightened, it may feel slightly rough. If excessive effort is required to turn the lock ring, the lock ring threads may not be correctly fitted onto the fuel tank threads. If this is the case, remove the lock ring and repeat Steps 43-46.
^ It is not necessary to replace the lock ring again if steps 43-46 are repeated.
47. Visually inspect for uneven gap(s) between the top inner edge of the lock ring and the top of the fuel pump.
^ If no uneven gaps are noted, proceed to the next step.
^ If any uneven gaps are present, remove the lock ring and repeat Steps 43-47.
NOTE:
It is not necessary to replace the lock ring again if Steps 43-47 are repeated.
48. Using the production date of the fuel tank from Step 23, install a 19 mm socket onto the SST and tighten the lock ring until the lock ring arrow is in the correct position.
NOTE:
The lock ring can be rotated a maximum of 1-3/4 turns.
NOTE:
There are two (2) correct positions for the lock ring arrow depending on the fuel tank production date.
^ Fuel tank date on or before 03/02/03: Lock ring arrow should be between 9:00 & 12:00.
^ Fuel tank date on or after 03/03/03: Lock ring arrow should be between 12:00 & 3:00.
NOTE:
The 12:00 location is oriented at the two (2) molded ribs of the fuel tank.
49. To ensure that the lock ring has reached minimum torque, mount a "click" type torque wrench on the top of the SST and apply 50 Nm (36.8 ft. lbf.) to the lock ring. The torque wrench should "click" and the lock ring should not rotate beyond the correct position.
NOTE:
Ensure the white molded arrow on top of the fuel pump has not moved and is still centered between the molded ribs on the fuel tank. If the arrow is not centered, the fuel gauge may read incorrectly.
50. Remove both SSTs (Fuel Pump Ring Removal Wrench and Fuel Pump Position Retainer).
51. Using the SST (Fuel Pump Lock Ring Gauge) attempt to insert the thickest side (6.0 mm) between the bottom of the lock ring and the fuel tank.
52. Check all twelve (12) points around the lock ring (in between each lock ring rib).
^ If the SST can be inserted into any of the twelve (12) points of the lock ring, remove the lock ring and repeat Steps 43-52.
^ If the SST cannot be inserted into any of the twelve (12) points of the lock ring, proceed to the next step.
53. The plastic cage may have fallen off during removal of the fuel line. Reinstall the cage by first aligning the grooves on the cage to the grooves on the fuel line, then push the cage inward.
NOTE:
There are four (4) grooves on the fuel line. Make sure to use the smaller grooves.
54. Reinstall the green fuel line retainer clip.
NOTE:
^ Position the clip so the tab is pointing towards the fuel line hose.
^ Align the lock tab to the fuel line openings and install the retainer clip.
55. Reinsert the fuel line into the fuel pump coupler by snapping it into the coupler until a "click" noise is heard.
NOTE:
To ensure that the fuel line is fully secure into the fuel pump coupler, slightly tug on the fuel line.
56. Reconnect the gray and black connectors.
57. Reconnect the negative battery cable.
58. Turn the ignition to the "ON" position.
59. Fuel the vehicle until the fuel gauge reads between 1/4 and 1/2,
NOTE:
The fuel level must not be more than 1/2 to run the WDS EVAP test.
60. Crank the engine until it starts and ensure there is no fuel leakage at the fuel line.
61. Turn the engine off.
62. Perform EVAP test using WDS.
^ If the vehicle passes the WDS EVAP test, proceed to the next step.
^ If the vehicle fails the WDS EVAP test, repeat "D. REPAIR PROCEDURE (Replacement of Fuel Tank, Fuel Pump Lock Ring & Fuel Pump Seal)" beginning with Step 29. It is not necessary to replace the fuel pump lock ring and fuel pump seal again.
63. Reinstall the fuel pump access cover.
64. Reinstall the seat bottom.
NOTE:
Prior to installing the seat bottom, feed all seat belts through bottom of seat cushion.
65. Reprogram all of the customer's preset radio stations.
66. Proceed to "E. AUTHORIZED MODIFICATION LABEL INSTALLATION."
67. Return the vehicle to the customer.