Five Hundred AWD V6-3.0L VIN 1 (2005)
6.
Remove EVAP canister and check for liquid fuel when the quick connect is removed or the canister is tipped down. Was excess amount of fuel
seen? Excess would leave a 10" (25 cm) diameter circle on a flat surface.
a.
Yes - Remove the sending unit access cover on the vehicle right side and remove the sending unit. Inspect the large vapor line quick connect
connection to the bottom side of the sender flange, and if not fully seated, fully seat the connector, reinstall sender using new gasket. If the
connector was properly installed remove and replace the fuel tank and the carbon canister. Repair complete.
b.
No - Go to Step 9.
7.
Inspect the fill pipe for any blockage. Note an object like a nut that will fit through the 13/16" (21 mm) hole at the top of the pipe should fall freely
through the remainder of the pipe. Was blockage found?
a.
Yes - Remove the blockage or replace the fill pipe. Drain the fuel to less than 1/2 tank prior to reinstalling the pipe. Repair complete.
b.
No - Go to Step 8.
8.
Remove secondary sending unit on left side of vehicle and inspect tank valve body. Valve body is about 3 1/2" (9 cm) in diameter (about size of a
baseball) and is located rearward of opening for Five Hundred/Montego and forward of opening for Freestyle. With one finger, push plunger
located in center of bottom plate up 1/2" (13 mm). Plunger should move freely and fall when let go. Does plunder move freely?
a.
Yes - Go to Step 10.
b.
No - Remove and replace the fuel tank. Repair complete.
9.
Replace the canister with a new lower restriction canister. Repair complete.
10.
Reassemble vehicle.
11.
Refuel to three automatic click offs and confirm vehicle fills okay and voltage remains below 3.6 volts. Observe the fuel gauge reading after
refueling. Does fuel gauge show above full, correctly indicating fuel level?
a.
Yes - System is okay.
b.
No - Go to Step 12.
12.
Check the FLI reading in the cluster. Does reading on the secondary side read XXX or higher? Enter Instrument Cluster Self-Diagnosis Mode
following instructions in Workshop Manual (WSM), Section 413-01. Check F1 XXX or FDM fuel level XXX RADS and F2 XXX or JPM FUEL
LVL XXX RADS. Are both numbers 210 or higher?
a.
Yes - Reading correct and the system is operating properly.
NOTE
THE CLUSTER MAY BE IN SLOW IN UPDATING FROM 7/8 TO FULL.
b.
No - Refer to TSB 06-17-2 Fuel Gauge Erratic/Inaccurate and install sender service kit.
Procedure I - Fuel Filler Housing Removal And Installation
WARNING
DO NOT CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED
COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND CAN IGNITE. FAILURE TO FOLLOW THESE
INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.
WARNING
DO NOT CARRY PERSONAL ELECTRONIC DEVICES SUCH AS CELL PHONES, PAGERS OR AUDIO EQUIPMENT OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT
AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.
WARNING
THIS PROCEDURE INVOLVES FUEL HANDLING. BE PREPARED FOR SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL
HANDLING PRECAUTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY.
1.
Release the fuel tank filler cap and position aside.
2.
Remove the two (2) bolts from the top of the fill pipe through the fill door.
