Fuel System - Fuel Tank Difficult to Refuel

Classification:
FE05-003

Reference:
ITB05-031

Date:
June 14, 2005

2003-2005 G35 AND FX; FUEL TANK DIFFICULT TO FILL AT TIMES

APPLIED VEHICLE(S):
2003-2005 G35 (V35) and (CV35)
2003-2005 FX (S50)

IF YOU CONFIRM

The fuel tank is intermittently difficult to fill.

ACTION





Replace the shutter valve inside of the fuel tank. (see fuel tank cut-away view, Figure 1)

IMPORTANT:
The purpose of ACTIONS (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire Service Procedure as it contains information that is essential to successfully completing this repair.





PARTS INFORMATION

CLAIMS INFORMATION





Submit a Primary Failed Part (PP) line claim using the claims coding shown.

SERVICE PROCEDURE

1. Release the fuel pressure from the fuel system using CONSULT-II (or other suitable method). Follow the procedure in the "EC" section of the ESM.

2. Use a suitable device to remove as much fuel as possible from the fuel tank.

WARNING:
Follow all CAUTIONS and WARNINGS provided in the Service Manual.

3. Remove the fuel level sensor. Refer to the FE section of the ESM.

WARNING:
The fuel level sensor opening and internal baffle have edges that are sharp.

4. You'll be working inside the fuel tank. To prevent injury place a split piece of rubber vacuum hose electrical harness cover tape or other suitable covering





^ Apply tape onto the edge of the fuel level sensor opening. (see Figure 2)





^ Apply an electrical harness cover to the edge of the vented baffle inside the tank. (see Figure 3 cut-away view from bottom of tank)

5. Reach inside the tank and gently bend the baffle away from you so you can reach under it. However don't overdo it. If you bend it too far you won't be able to reach the shutter valve on the end of the tank inlet.





6. Remove the shutter valve with a twisting motion while pulling it straight off. (see Figure 4 cut-away view from bottom of tank)

7. Install the shutter valve listed in the Parts Information section of this bulletin.

^ Push it on the end of the tube with a twisting motion

^ Turn it until a "snap" is heard and felt

^ Confirming the tab locks to the hole. (shown in Figure 4)





^ The hole is on the end of the fuel inlet tube. (see Figure 5)

8. Gently bend the baffle back to it's original position.

9. Remove the protectors you installed to the tank in step 4. (opening and baffle)

10. Install the new fuel level sensor 0-ring in the groove on the fuel tank.

11. Re-install the fuel level sensor on the fuel tank. Refer to the FE section of the ESM.

12. Add the removed quantity of fuel to the tank.





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