Ninety-Eight V6-3800 3.8L (1989)
a.
Place "no smoking" signs near work area.
b.
Be sure to have C02 Dry Chemical (Class B) fire extinguish handy.
c.
Wear safety glasses.
d.
Siphon or pump fuel into an explosion proof container.
e.
Avoid fuel spillage - gasoline fumes are heavier than air and will collect at floor level.
f.
Wear gloves to protect against sharp edges.
2.
Fuel pressure relief procedure:
CAUTION: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system
components. To do this:
a.
Disconnect fuel tank harness connector.
b.
Crank engine, engine will start and run until fuel supply remaining in fuel lines is consumed. Engage starter for 3.0 seconds to assure relief of any
remaining pressure.
c.
Turn ignition off. Unless this procedure is followed before servicing fuel lines or connections, fuel spray could occur.
3.
Drain fuel tank using hand operated pump.
CAUTION: Never drain or store gasoline in an open container due to the possibility of fire or explosion.
4.
Disconnect the negative battery cable.
5.
Hoist vehicle, see Section 0A of the Service Manual.
CAUTION: To help avoid personal injury when a car is on a hoist, provide additional support for the car at the opposite end from which
components are being removed. This will reduce the possibility of the car failing off of the hoist.
6.
Disconnect the fuel feed and return lines at the body rail, using back-up wrenches. Cap the fuel lines to reduce spillage.
7.
Loosen the hose clamp and disconnect the vapor hose.
8.
Loosen clamps and disconnect the filler neck and vent hose. Remove two exhaust hanger bolts at rear and lower exhaust enough to gain access to
fuel tank. Support exhaust with jack stand or cable, etc. Loosen exhaust heat shield and let hang free on pipe. Remove parking brake cable bracket
at left fuel tank strap.
9.
Support fuel tank and loosen the tank strap bolts and lower the fuel tank.
10.
Loosen the fuel sender cam lock ring using special tool J 24187-A.
11.
Remove the fuel sender assembly and transfer the lock ring and the two pipe insulators onto the new sender.
12.
Install new O-ring gasket on tank opening.
13.
Install new fuel sender and pump assembly (part number 25094448) with a rollover valve into the tank.
^
Use care not to damage or deform pipe or break solder connection at sender cover.
^
Use care in installing the sender to not damage the float assembly.
14.
Rotate cam lock ring to the stops using the special tool J 24187-A.
15.
Verify that the fuel sender pipes are insulated from top of the fuel tank.
16.
Verify fuel tank and underbody noise isolation rubber strips remain in proper position.
17.
Install fuel tank to vehicle. Tighten strap bolts to 34 N-m (23 ft.lbs.).
18.
Reconnect the filler neck and torque clamps to 2.5 N-m (20 in.lbs.).
