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I took my '01 Aero Wagon to the dealer (Barrier, in Belleview WA) to get the fuel tank baffle kit installed. The shop had never done this before, so they were unsure of what exactly was involved. I made sure that the fuel level was as low as practical (below 1/4) to make it easier for the technician.
The baffle is a contorted, white, flexible plastic piece that is shaped roughly like the letter "U" with a crosspiece connecting the two free ends to give it rigidity. It is designed to fold and compress so that it can be inserted through the fuel pump opening, and then it is popped open and maneuvered into position inside the tank. The detailed instructions indicate that it can be installed with the tank in the car, but it would be "easier" with the tank removed.
The Barrier technician tried the in-car route and decided the risk to the interior was too great, so he removed the complete exhaust system and the fuel tank and did the installation at the workbench. He said it was really tricky to get the baffle into just the right position. He looked pretty unhappy - I gather it was not a fun job.
Three hours later (including complimentary wash) I was on my way. I won't know for a while if the thump is gone because I had a brain fart and filled the tank all the way up. I will have to wait until the level drops to see how effective the fix is.
I wanted to notify the Forum so that anyone interested in the fix would allow enough time to get it done. I suggest that the fix be combined with a scheduled service so you can just leave the car for a day and not have to spend several hours kicking your heels in the waiting area.
I'll post another note about the thump reduction later.
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