Fuel Tank - Slow Fill Or Unable To Fill

NO: 14-08-96

GROUP: Fuel

DATE: Aug. 2, 1996

SUBJECT:
Fuel Tank - Slow
Fill Or Unable To Fill
Completely

MODELS:

1996 PL Neon

NOTE:
THIS BULLETIN APPLIES TO NEON'S BUILT WITH A PLASTIC FUEL TANK FROM AUGUST 20, 1995 (MDH 08-20-xx) TO AUGUST 24, 1995 (MDH 08-24-XX).

SYMPTOM/CONDITION:

Fuel tank may be slow to fill, will not fill and/or the fuel gauge does not read full when the vehicle fuel tank is full. The gauge may also stay in the full position and then drop down suddenly. If any of the above symptoms exist, proceed to the repair procedure.

PARTS REQUIRED:

1 5278089 Fuel Tank Assy (Including Fuel Pump Assy.)

CAUTION:
STEEL AND PLASTIC TANKS ARE NOT INTERCHANGEABLE. VEHICLES EQUIPPED WITH THE STEEL TANK SHOULD NOT USE THIS PART NUMBER.

REPAIR PROCEDURE:

This bulletin involves the replacement of the fuel tank assembly with a revised assembly.

1. Perform the fuel system pressure release procedure in the 1996 Neon Service Manual (Publication No. 81-270-6025) on page 14-7.

2. Disconnect the battery and drain the fuel tank following the procedure given in the 1996 Neon Service Manual (Publication No. 81-270-6025) on page 14-7.

3. Raise the vehicle on a suitable hoist for tank removal.

CAUTION:
SHOP TOWELS SHOULD BE WRAPPED AROUND THE FUEL HOSES TO CATCH ANY GASOLINE THAT MAY SPILL.

4. Disconnect the fuel pump module electrical connector.

5. Disconnect the fuel tube from the fuel filter/regulator.

6. Support the tank with a transmission jack, loosen tank mounting straps and lower the tank slightly.

7. Disconnect the fuel filler tube and filler vent tube from the filler hose at the fuel tank.

8. Disconnect the fuel filler vapor tube from the tee connecting it to the tank vapor relief tube and Evap canister tube.

9. Disconnect the vapor line from the Evap canister tube.

10. Remove the tank mounting straps and lower tank.

11. Position new fuel tank and pump assembly (P/N 5278089) on the transmission jack.

12. Raise the tank into position. Connect the fuel filler tube tank inlet nipple and insure proper fit of the fuel filler vent tube fitting.

13. Torque the fuel tank strap nuts to 23 Nm (250 in. lbs.). Insure that straps are not twisted or bent and then remove transmission jack.

14. Attach the fuel tubes to the pump module and chassis fuel tube.

15. Connect the fuel vapor tube to the tee and then to the Evap canister tube.

16. Attach the electrical connector to the fuel pump module.

17. Lower the vehicle.

18. Fill the fuel tank, install the filler cap and connect the battery cable.

CAUTION:
WHEN USING THE ASD FUEL SYSTEM TEST, THE AUTO SHUTDOWN (ASD) RELAY REMAINS ENERGIZED FOR EITHER 7 MINUTES, OR UNTIL THE TEST IS STOPPED, OR UNTIL THE IGNITION SWITCH IS TURNED TO THE OFF POSITION.

19. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks and repair as needed.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: 14-60-02-92 0.7 Hrs.

FAILURE CODE: P8 - New Part