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Sure thing... here's the quick version. It seems to me that almost all MY99's will eventually have this problem.
Under the rear seat is the access to the fuel pump, the repair can be done via this hole. Open this up - on the leading edge of the visible tank (to the side of the pump) you'll see a small valve that looks like a vent with wires connected - this sits on the pedistal which leaks.
Now you need to jack the rear of the car up and lower (not remove) the tank. Take the passenger side strap (from bottom) an loosen the holding bolt (on front edge) as much as possible (leaving just enough thread to support the tank - do this only when the tank is down to 1/8th or less fuel to make the job easier). Then the strap on the drivers side remove all the way - this will drop this half of the tank down enough (couple of inches) to allow you to work on it from the top.
Now remove the single screw that holds in the pressure sensor and remove it. You'll see the pedistal - mine had a crack in it. I suggest removing this little pedistal if possible. Now you can put the valve back into the remaining hole (directly into tank) and use the epoxy to build up this joint and make the valve fused into the tank. Don't skimp here - plenty of epoxy - you're basically fusing the two together vapor tight. After using several products that didn't work I came across a fuel tank sealing epoxy designed for fuel tank seams in aircraft. You can get this from Aircraft Spruce. This has held up well and is easy (if messy and smelly) to work with.
Once you get it in you just need to use your knees under the car to lift the tank back into position and redo the straps to hold the tank.
This repair has now lasted quite a while, removed all fuel odor, and I've had no further error codes/lights - and have passed AZ emissions without problem.
Let me know if you have any additional questions, good luck!
Take Care,
Scott
posted by 208.248.3...
, Wed, 18 Apr 2007 09:42:55
, Wed, 18 Apr 2007 08:49:41
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