So, after months of searching, testing parts, replacing rubber connectors, checking lines, swapping filler necks, and buying a new gas cap, I have finally narrowed the problem down to the gas tank. I had my Dad help me drop it today to see what we could find.

We had some trouble getting the straps off; even had to saw through one of them. Lowered the exhaust by unbolting the muffler hangers (if you don't move the pipe, it makes it really hard to get the tank out properly).

Here it is, our culprit. The fuel tank pressure sensor. The "head" is snapped right off. I had to use some pliers to pull it out of the hole in the tank. It looks like someone actually tried to glue it back together after it broke. I also looked at the date imprinted on the bottom and discovered that it'* the OE one from the factory.




We are convinced that someone (a prior owner) had serviced the tank before, and did a poor job of putting it all back together. My theory is that the sensor somehow got broken while they were working on the tank and they just never replaced it.

And while I'm down there... I decided to replace the fuel sender lock ring and fuel pump strainer. Old vs. new in the next pic.


I'll be putting it all back together in the morning. Next up on the list is a rear brake overhaul with new drums, shoes, wheel cylinders and springs.

Good find, thanks for sharing. I'll have to add that to the P0440 list.

Great info- thanks for posting.

Great info and awesome find. Thanks for throwing up some pictures as well. The difference between the new and old strainer is remarkable.

Sounds like someone was changing the fuel pump and when they were putting the tank back up hit...

No problem guys, glad I could help.

For those who don't know, the fuel tank pressure sensor is located on the driver'* side of the tank. You can see the hole that the end of the sensor plugs into. It also has a little plastic piece that clips onto the tank to help protect the sensor.


We used a hanger to tie back the hoses because gas was coming out of them while we pulled the tank down. Only had about 3-4 gallons in the tank before lowering it.


This is the sensor'* hole, and the metal frame that the protective plastic clips onto.

My cell camera takes much better pictures in real sunlight.

While you have the tank out you might as well knock out the fuel pump!!!