Service Procedure

WARNING:
GASOLINE AND GASOLINE VAPORS ARE EXTREMELY FLAMMABLE. BEFORE PERFORMING THIS INSPECTION AND/OR REPAIR PROCEDURE ENSURE THERE ARE NO OPEN FLAMES OR IGNITION SOURCES IN THE WORK AREA. ALSO, MAKE SURE THE WORK AREA IS WELL VENTILATED.

A. Inspect Fuel Tank Control Valve

1. Release fuel system pressure using the following procedure:

a. Remove and save the rear seat cushion.

b. Remove and save the rear seat cushion silencer pad.





c. Remove and save the plastic fuel pump module access cover (Figure 1).

d. Disconnect the electrical connector at the fuel pump module (Figure 1).

e. Start and run the engine until it stalls.

f. Attempt restarting the engine until it will no longer run.

g. Turn the ignition key to the "OFF" position.

2. Using a shop vacuum, clean the top of fuel pump modules and fuel tank to remove loose dirt and debris.

3. Drain all of the fuel from the fuel tank

4. Disconnect and isolate the negative battery cable.

5. Disconnect the fuel supply hose at the fuel pump module (Figure 1).

CAUTION:
Wrap a shop towel around the fuel supply hose to prevent gasoline spillage.





6. Using the fuel pump module Lock Ring Wrench 9340 or equivalent, remove and save the fuel pump module lock ring (Figure 2).





7. Carefully remove and save the fuel pump module from the fuel tank (Figure 3).

CAUTION:
Immediately place the fuel pump module into a clean drain pan to prevent spilling any fuel onto the vehicles interior.





8. Using the provided oversized inspection mirror (P/N 375) and a Light Emitting Diode (LED) flashlight, inspect the bottom of the control valve (Figure 4).

> If the bottom cover of the control valve is not broken (Figure 5), continue with Step 9 of this procedure.

> If the bottom cover of the control valve is broken (Figure 5), continue with Section B. Fuel Tank and Vapor Canister Replacement.

9. Remove and discard the original fuel tank module O-ring and install a new fuel tank module O-ring.

10. Place the original fuel pump module into the fuel tank opening.

11. Using the fuel pump module Lock Ring Wrench 9340 or equivalent, install the fuel pump module lock ring (Figure 2).

12. Connect the fuel supply hose to the fuel pump module (Figure 1).

13. Connect the electrical connector at the fuel pump module (Figure 1).

14. Install the plastic fuel pump module access cover (Figure 1).





15. Install the rear seat cushion silencer pad (Figure 6).

16. Install the rear seat cushion.

17. Fill the fuel tank with the same amount of fuel that was removed.

18. Connect the negative battery cable.

19. Continue with Section C. Check for Fuel Leaks and Clear Diagnostic Trouble Codes (DTCs).

B. Fuel Tank and Vapor Canister Replacement

NOTE:
The following procedure is required if the fuel tank control valve requires replacement per the inspection in Section "A." Very few vehicles are expected to require this repair.

1. Lift the vehicle on an appropriate hoist.





2. Remove and save the left and right underbody plastic splash shields (Figure 7).

3. For convertible models only, remove and save exhaust system from the underbody exhaust connector back (Figure 8).





4. For convertible models only, remove and save the rear cross-brace front retaining bolts (Figure 9).





5. For convertible models only, place a small spacer block under the rear cross-brace forward mounting points to gain access for fuel tank removal (Figure 9).

6. Disconnect the fuel filler tube from the fuel tank fill port.

7. Disconnect the fuel supply hose at the fuel tank.

8. Disconnect the vapor canister vent hose at the fuel tank.

9. Disconnect the vapor canister control hose at the fuel tank.





10. Place a transmission jack under the fuel tank (Figure 10).

11. Remove and save the right and left fuel tank straps (Figure 10).

12. With the help of an assistant, carefully lower the fuel tank from the vehicle.

13. With the help of an assistant, remove the fuel tank from the transmission jack and place the fuel tank on the floor.

14. Transfer the following components from the original fuel tank to the new fuel tank:





> Fuel tank wiring (Figure 11).

> Fuel tank heat shield (Figure 11).

> Fuel tank fuel supply hose (Figure 11).

15. Place a new fuel pump module O-ring around the fuel pump module opening.

16. Place the original fuel pump module into the fuel tank opening (Figure 11).

17. Using the fuel pump module Lock Ring Wrench 9340 or equivalent, install the fuel pump module lock ring (Figure 11).

18. Connect the fuel supply hose to the fuel pump module (Figure 11).

19. With the help of an assistant, place the fuel tank onto the transmission jack.

20. Raise the fuel tank into position and install the fuel tank mounting straps.

Tighten the fuel tank strap bolts to 35 ft. lbs. (48 Nm).

21. Connect the vapor canister control hose at the fuel tank.

22. Connect the vapor canister vent hose at the fuel tank.

23. Connect the fuel supply hose at the fuel tank.

24. Connect the fuel filler tube to the fuel tank fill port.

25. For convertible models only, remove the spacer blocks placed under the cross-brace at the right and left forward cross-brace mounting points.

26. For convertible models only, install the rear cross-brace front retaining bolts.
Tighten the bolts to 37 ft. lbs. (50 Nm).

27. For convertible models only, install the exhaust system.

28. Install the left and right underbody plastic splash shields (Figure 7).

29. Replace the vapor canister using





a. Disconnect the inlet air vent hose at the vapor canister (Figure 12).

b. Disconnect the fuel tank vent hose at the vapor canister (Figure 12).

c. Disconnect the control hose at the vapor canister (Figure 12).

d. Disconnect the vapor canister electrical connector (Figure 12).

e. Remove and save the two vapor canister mounting nuts.

f. Remove and discard the original vapor canister.

g. Place the new vapor canister into position and start the mounting nuts.

Tighten the nuts to 50 in. lbs. (5.5 Nm).

h. Connect the vapor canister electrical connector (Figure 12).

i. Connect the control hose at the vapor canister (Figure 12).

j. Connect the fuel tank vent hose at the vapor canister (Figure 12).

k. Connect the inlet air vent hose at the vapor canister (Figure 12).

30. Lower the vehicle from the hoist.

31. Connect the electrical connector at the fuel pump module (Figure 1).

32. Install the plastic fuel pump module access cover (Figure 1).

33. Install the rear seat cushion silencer pad and seat cushion (Figure 6).

35. Fill fuel tank with the same amount of fuel that was removed.

36. Connect the negative battery cable.

37. Continue with Section C. Check for Fuel Leaks and Clear Diagnostic Trouble Codes (DTCs).

C. Check for Fuel Leaks and Clear Diagnostic Trouble Codes (DTCs)

1. Connect the wiTECH VCI pod to the vehicle data link connector located to the right of the park brake pedal.

2. Place the ignition in the "RUN" position.

3. Open the wiTECH Diagnostic application.

4. Starting at the "Select Tool" screen, highlight the row/tool for the wiPOD device you are using. Then select "Next" at bottom right side of the screen.

5. Enter your "User id" and "Password", then select "Finish" at the bottom of the screen.

6. From the "Vehicle View" screen, select the "PCM" icon.

7. Select the "Actuator" tab.

8. Highlight "Fuel Pump Relay Control State" and select the green arrow.

9. Check the fuel system for leaks.

10. Select "Stop All Actuators".

11. Return to the "Vehicle View" screen.

12. From the "Vehicle View" screen, click on "All DTCs" tab.

13. Select "Clear Stored DTCs" tab located on the right side of the screen.

14. Click "OK" on the Pop-Up screen.

15. Remove the wiTECH equipment from the vehicle.