C. Repair Procedure

Follow the procedure described below when performing the Safety Recall Campaign and refer to the appropriate 1999 Service Manual (99500-67D00-33E), 2000 Service Manual (99500-65D10-33E) or 2001 Service Manual (99500-65D20-33E) for additional information.

CAUTION:
The following work must not be performed when the engine is hot as this may cause damage to the catalyst.

WARNING:
The following work must be completed with no smoking, in a well ventilated area and away from any open flames.

1. Place the transmission gear shift lever in neutral (shift selector lever to "P" range for A/T vehicles), set the parking brake and block the drive wheels.





2. Remove the fuel pump relay (Figure 4).

3. Remove the fuel filler cap to relieve fuel pressure in the fuel tank, then reinstall it.

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.

5. Record radio station presets, then disconnect the negative cable from the battery.





6. Remove the plastic cover at the top of the engine, the surge tank pipe and surge tank pipe gaskets (Figure 5).

7. Remove the vacuum hose from its connections to the surge tank and from the fuel pressure regulator.





8. Remove the bolts from the fuel pressure regulator and remove the fuel pressure regulator (Figure 6).

WARNING:
A small amount of fuel may be released when the fuel pressure regulator is removed from the delivery pipe. Place a shop cloth under the delivery pipe to absorb the released fuel.

9. Disconnect the fuel return hose from the fuel pressure regulator.

WARNING:
A small amount of fuel may be released when the hose is disconnected. Cover the hose with a shop cloth.

10. Connect the campaign fuel pressure regulator to the fuel return hose and place the clamp into position.





11. Apply a thin coat of gasoline to the 0-ring on the new fuel pressure regulator and insert the fuel pressure regulator into the delivery pipe (Figure 7). Install and tighten the fuel pressure regulator bolts to the specified torque.

Tightening torque:
10 N.m (1.0 kg-m, 7.5 lb-ft)

12. Remove the fuel pressure regulator vacuum hose union from the surge tank using locking pliers and pry bar.





NOTE:
Double nut and remove stud as shown (Figure 8). This will provide better access to remove hose union using locking pliers and pry bar.





13. Apply thread lock (99000-32030) to a 10 mm portion of the outer surface of the smaller OD end of the campaign fuel pressure regulator vacuum hose union (Figure 9). The tip of the smaller OD end of the campaign fuel pressure regulator vacuum hose union is chamfered. Using a bronze drift pinch and hammer, drive the new fuel pressure regulator vacuum hose union into the surge tank with the small OD end (chamfered) facing inward. Stop when the union reaches the step between the smaller OD end and larger OD end. At this point the campaign fuel pressure regulator vacuum hose union will extend 15 mm from the surge tank.

14. Install the vacuum hose to the surge tank vacuum hose union and fuel pressure regulator.





15. Install the new surge tank pipe gaskets and surge tank pipe. Tighten the surge tank pipe mount nuts and bolts to the specified torque (Figure 10).

Nut Tightening torque:
23 N.m (2.3 kg-m, 16.5 lb-ft)
Bolt Tightening torque:
10 N.m (1.0 kg-m, 7.0 lb-ft)

16. Install the fuel pump relay.

17. Connect the negative cable to the battery and reset the radio stations and clock.

18. Turn ON the ignition switch for 3 seconds (to operate the fuel pump) and then turn it OFF. Repeat this cycle 3 or 4 times to fully pressurize the system. With the ignition switch OFF confirm that there is no leakage from any part of the fuel system. Run the engine and confirm that there are no leaks.