Required Operations

Before starting the PROCEDURE section of this bulletin, CHECK ON THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.

1. Remove the fuel tank from the vehicle as follows:

WARNING:
_ Gasoline is extremely flammable and explosive. Park the vehicle in a well-ventilated area. Make certain that no ignition sources (i.e., pilot lights, cigarettes and lighters, electrical motors and switches, etc.) are near the repair area. Gasoline vapors are heavier than air, will travel along the ground, and can find an ignition source that is several yards away from the gasoline.
_ Be sure that fire extinguishers are located in the immediate repair area.
_ Wipe up any gasoline spills immediately.
_ Do not remove the fuel tank if it is over 2/3 full. If the fuel tank level is over 2/3 full, drain as much fuel as possible into an unbreakable, non-dissolvable container. When as much fuel as possible has been drained, continue with this procedure.





a. Remove the drain plug and drain plug gasket. Drain all of the fuel from the tank into an approved fuel storage container.

b. Remove the fuel tank from the vehicle. Refer to Group 13 of the appropriate service manual.





2. Inspect for evidence of fuel leakage in the spot-welded area (shown above) by checking for:
_ Fuel odor
_ Loss of paint on top of fuel tank in the indicated area
_ Discoloration or staining on top of fuel tank in the indicated area
_ Moisture (fuel) in the indicated area

IMPORTANT:
> If NO evidence of fuel leakage is observed, go to Step 3 for protector plate installation instruction.

> If evidence of fuel leakage is observed, go to step 4 for fuel tank replacement instructions.

3. If evidence of fuel leakage is observed, install a protector plate (listed in the PARTS INFORMATION section of this bulletin) to the top of the fuel tank over the spot weld points as follows:

a. Using a rag soaked with 3M 08987 Cleaner (or equivalent), remove dirt and grease from the top of the fuel tank in the spot-welded area. Allow to dry for 2 to 3 minutes.





b. Using a small brush, apply 3M Urethane Primer 08684 or equivalent to the spot-welded area.





C. Clean the protector plate, using 3M 08987 Adhesive Cleaner (or equivalent).

d. Using a small brush, apply 3M Urethane Primer 08684 or equivalent to one side of the protector plate. Allow the primer on the tank and the protector to dry for approximately 5 minutes.





e. Apply a 5 mm-thick coating of 3M Super Fast Urethane Adhesive 08609 over the primer on the fuel tank. (DO NOT USE SILICONE SEALANT) Apply the adhesive over the entire area circled in the illustration.





f. Affix the protector over the adhesive. Center the protector on the flat area, with the hole in the protector toward the front of the tank as shown.





g. Press the protector down by hand onto the tank, compressing the adhesive to 2 mm thickness.

h. Reinstall the fuel tank. Refer to Group 13 in the appropriate service manual.

4. If any evidence of fuel leakage is observed, replace the fuel tank as described in Group 13 of the appropriate service manual. Use the fuel tank kit listed in the PARTS INFORMATION section of this bulletin.





a. Remove the fuel pump and gauge assembly and gasket, fuel gauge assembly and gasket, cut-off valve assembly, vapor hose, 3 vapor hose clips, and the return hose clip.

b. If the vapor hose is damaged, replace it.

c. Install the cut-off valve, fuel gauge, and fuel pump and gauge assembly into the new fuel tank, using the new gaskets and clips provided in the kit. Re-use the original cut-off valve gasket unless the gasket appears to be damaged.

CAUTION:
When installing the fuel gauge on the new tank, be sure to install the fuel gauge assembly correctly. If the connector is not positioned correctly, the fuel level reading will be incorrect. Align the connector in one of the following positions, depending upon the hole pattern:





If the fuel gauge hole pattern does not have a hole directly above the connector as shown, position the connector toward the front of the tank as shown:





If the fuel gauge hole pattern has a hole directly above the connector as shown, position the gauge so that the connector is positioned 30 degrees counterclockwise:





d. Tighten the bolts to the following torque specifications:

e. Install the fuel tank into the vehicle. Refer to Group 13 of the appropriate service manual.

IMPORTANT:
Dispose of the old fuel tank immediately. Consult your dealership's legal counsel for Federal, state, and local laws or regulations pertaining to proper disposal of the old fuel tank.