Inspection Procedure

1. WITH IGNITION KEY IN THE RUN POSITION, CHECK FUEL GAUGE TO INSURE THERE IS NO MORE THAN 3/4 OF A TANK OF FUEL IN VEHICLE. NOTE FUEL GAUGE READING FOR REFERENCE IN PERFORMING STEP 9.

NOTICE:
IN CASES WHERE GAUGE INDICATES ABOVE 3/4 OF A TANK OF FUEL, REMOVE ENOUGH FUEL FROM TANK SO THAT A 3/4 GAUGE READING IS INDICATED. FOLLOW "DRAINING FUEL TANK" PROCEDURE IN APPLICABLE SERVICE MANUAL SECTION 6C-6, ENGINE FUEL.

2. DISCONNECT NEGATIVE BATTERY CABLE AFTER NOTING RADIO SETTINGS SO THEY MAY BE RESET LATER.

3. REMOVE FUEL TANK FILLER CAP.

4. REMOVE FUEL FILLER DOOR AND CUP ASSEMBLY (6 ATTACHING SCREWS). INSTALL FILLER CAP AND ROTATE UNTIL AT LEAST THREE CLICKS ARE NOTED).

5. REMOVE LEFT REAR WHEEL WELL FUEL FILLER NECK SHIELD (2 ATTACHING SCREWS).

6. UNDERHOOD, IN AREA OF FUEL VAPOR CANISTER, LOCATE TANK PRESSURE CONTROL VALVE AND DISCONNECT VALVE FROM HOSE WHICH CONNECTS VALVE TO CHASSIS FORE-AFT FUEL VAPOR PIPE.

7. DISCONNECT RADIATOR TEST CAP FROM RADIATOR PRESSURE TEST PUMP (KENT- MOORE TOOL J-24460-01 OR EQUIVALENT) AT HOSE TO CAP FITTING.

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

8. INSERT THREADED END OF RADIATOR PRESSURE TESTER HOSE FITTING INTO HOSE CONNECTED TO CHASSIS FORE-AFT VAPOR PIPE.

9. AT A RATE OF TWO (2) STROKES PER SECOND, PRESSURIZE FUEL SYSTEM WITH APPLICABLE NUMBER OF FULL STROKES OF RADIATOR PRESSURE TESTER HAND PUMP AS INDICATED BELOW BY FUEL GAUGE READING:

FUEL GAUGE READING NUMBER OF STROKES

EMPTY TO 1/4 50 1/4 TO 1/2 45 1/2 TO 3/4 35

10. IMMEDIATELY PROCEED TO REAR OF VEHICLE AT FUEL FILLER DOOR OPENING. WORKING THROUGH THE WHEEL WELL ACCESS OPENING AND OBSERVING THROUGH THE QUARTER PANEL FUEL FILLER DOOR OPENING, APPLY A LIBERAL AMOUNT OF SNOOP LIQUID LEAK DETECTOR (KENT-MOORE J-41365) COMPLETELY AROUND FUEL TANK TO FILLER NECK SOLDER JOINT FOLLOWING INSTRUCTIONS ON CONTAINER.

NOTICE:
A FLASHLIGHT OR OTHER LIGHT SOURCE SHOULD BE USED TO ILLUMINATE AREA BEING INSPECTED.

11. VISUALLY INSPECT ENTIRE AREA AROUND SOLDER JOINT AND, BASED ON WHETHER OR NOT BUBBLES APPEAR IN SNOOP LIQUID LEAK DETECTOR, PROCEED AS INDICATED BELOW:

A. BUBBLES APPARENT AROUND JOINT LEAK INDICATED, PROCEED DIRECTLY TO "FUEL TANK REPLACEMENT PROCEDURE" BELOW.

B. NO BUBBLES APPARENT AROUND JOINT SLOWLY LOOSEN FUEL FILLER CAP WHILE LISTENING FOR PRESSURE BEING RELEASED PAST THE FUEL FILLER CAP SEAL. IF PRESSURE RELEASE IS HEARD, PROCEED WITH REMAINDER OF "INSPECTION PROCEDURE" STEPS (STEPS 12 THRU 17)

NOTICE
IF PRESSURE RELEASE IS NOT HEARD REPEAT STEPS 9-11 INSURING THERE ARE NO LEAKS AT HOSE CONNECTIONS AND FILLER CAP. CORRECT LEAKS AS REQUIRED AND PROCEED WITH INSPECTION PROCEDURE.

12. DISCONNECT RADIATOR PRESSURE TEST PUMP FROM CHASSIS FORE-AFT VAPOR PIPE HOSE AND CONNECT TANK PRESSURE CONTROL VALVE TO HOSE. SECURE HOSE WITH EXISTING CLAMP.

13. INSTALL FUEL FILLER NECK SHIELD (2 ATTACHING SCREWS).

14. INSTALL FUEL FILLER DOOR AND CUP ASSEMBLY (6 ATTACHING SCREWS).

15. RECONNECT NEGATIVE BATTERY CABLE. RESET RADIO SETTINGS AND CLOCK.

16. IF FUEL WAS DRAINED FROM TANK IN STEP 1, REFILL TANK TO PREVIOUS LEVEL WITH FUEL THAT WAS DRAINED.

17. INSTALL CAMPAIGN IDENTIFICATION LABEL.

1. DISCONNECT RADIATOR PRESSURE TEST PUMP FROM CHASSIS FORE-AFT VAPOR PIPE HOSE AND CONNECT TANK PRESSURE CONTROL VALVE TO HOSE. SECURE HOSE WITH EXISTING CLAMP.

2. REPLACE EXISTING FUEL TANK AND FUEL SENDER ASSEMBLY O-RING GASKET WITH NEW COMPONENTS FOLLOWING APPLICABLE SERVICE MANUAL PROCEDURES SECTION 6C-6, ENGINE FUEL.

3. INSTALL FUEL FILLER DOOR AND CUP ASSEMBLY (6 ATTACHING SCREWS).

4. RECONNECT NEGATIVE BATTERY CABLE. RESET RADIO SETTINGS AND CLOCK.

5. IF FUEL WAS DRAINED FROM TANK IN STEP 1 OF INSPECTION PROCEDURE. REFILL TANK TO PREVIOUS LEVEL WITH FUEL THAT WAS DRAINED.

6. INSTALL CAMPAIGN IDENTIFICATION LABEL.