For 1990-2009 cars

Important:

• | If a fuel system problem is caused by contaminated fuel or other foreign material in the fuel tank, the tank must be cleaned. If the tank is rusted or is still contaminated after cleaning, the tank must be replaced.

• | Only use oil free compressed air to blow out the fuel pipes.

• | Inspect the fuel tank internally and clean the fuel tank if you find a plugged fuel filter.

1. Remove the fuel tank from the vehicle. Refer to Fuel Tank Replacement .
2. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
3. Remove the fuel tank pressure sensor from the fuel tank. Refer to Fuel Tank Pressure Sensor Replacement .
4. Remove the fuel cut-off valve from the fuel tank. Refer to Fuel Cut-Off Valve Replacement .

Important: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations.

5. Fill the fuel tank with hot water.
6. Shake the fuel tank vigorously for 5 minutes.
7. Drain the fuel tank.

Important: If the inside of the fuel tank contains any traces of rust after cleaning, replace the fuel tank.

8. Inspect that all of the water is removed from the fuel tank.
9. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
10. Install the fuel tank pressure sensor to the fuel tank. Refer to Fuel Tank Pressure Sensor Replacement .
11. Install the fuel cut-off valve to the fuel tank. Refer to Fuel Cut-Off Valve Replacement .
12. Install the fuel tank to the vehicle. Refer to Fuel Tank Replacement .
13. Refill the fuel tank.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

14. Connect the negative battery cable.

Tighten
Tighten the negative battery cable retainer to 8 N·m (72 lb in).

15. Inspect for leaks and repair as necessary.