Recall - Fuel Tank Check Valve Installation Supplement
12/01/93TO: ALL FORD DEALERS
THE PURPOSE OF THIS ANNOUNCEMENT IS TO PROVIDE ADDITIONAL INFORMATION REGARDING SAFETY RECALL 93S68:
SECTION I - ADDITIONAL TECHNICAL INFORMATION.
SECTION II - CANCELLATION OF PARTS KITS EE, FF, GG, AND HH AND INTRODUCTION OF PARTS KITS JJ AND KK.
SECTION III - HELPFUL HINTS FOR KIT INSTALLATION.
SECTION I - MODIFIED INSTALLATION PROCEDURE FOR REAR TANK CHECK VALVE - KITS CC AND DD:
ON 1992/93 F-SERIES EQUIPPED WITH A STEEL REAR FUEL TANK, TECHNICIANS MAY FIND IT DIFFICULT TO INSTALL THE CHECK VALVE ON THE REAR TANK. IF YOU ARE NOT CAREFUL WHEN LOWERING THE FUEL TANK, THE PORTS ON THE REAR TANK FUEL DELIVERY MODULE CAN BE BENT. THE FOLLOWING TECHNIQUE SHOULD BE FOLLOWED ON THE REAR TANK (NO CHANGE IN PROCEDURE IS NECESSARY ON THE FRONT TANK). NO CHANGE IN LABOR TIME IS REQUIRED:
1. DRAIN REAR FUEL TANK IF NOT ALREADY NEAR EMPTY. THIS CAN BE DONE BY PUSHING A LARGE HOSE DOWN THE FILLER NECK AND SIPHONING AS MUCH FUEL AS POSSIBLE USING ROTUNDA FUEL STORAGE TANKER 034-00002 OR 034-00014 OR EQUIVALENT.
2. RAISE VEHICLE ON HOIST AND POSITION SUITABLE SAFETY STANDS UNDER VEHICLE.
3. POSITION SPARE TIRE OUT OF THE WAY (IT IS NOT NECESSARY TO COMPLETELY REMOVE THE TIRE AND CARRIER - JUST REMOVE FROM THE HOLD DOWN BOLT AND LET THE TIRE AND CARRIER CAREFULLY SWING DOWN OUT OF THE WAY).
4. LOOSEN HOSE CLAMP AT FUEL FILLER HOSE CONNECTION TO FUEL TANK AND REMOVE HOSE FROM TANK OR, ALTERNATIVELY, REMOVE THE THREE SCREWS ATTACHING THE FILLER NECK TO THE BODY SHEET METAL.
5. POSITION SUITABLE JACK STAND UNDER REAR FUEL TANK.
6. SUPPORT THE TANK AND REMOVE THE BOLTS ATTACHING THE TANK SUPPORTS TO THE FRAME. SLOWLY BEGIN TO LOWER THE TANK WHILE KEEPING THE FRONT OF THE TANK UP AS THE TANK IS LOWERED FROM THE REAR FIRST. SEE FIGURE # 1. MOVE THE TANK A FEW INCHES REARWARD AS THE TANK IS BEING LOWERED - BE SURE THAT THE FUEL LINES AT THE FRONT OF THE TANK ARE MOVING FREELY AND NOT BINDING ON THE CROSSMEMBER. DO NOT LOWER THE TANK MORE THAN 4-5 INCHES. THIS WILL PROVIDE ACCESS TO THE FUEL DELIVERY MODULE AT THE FRONT OF THE TANK. SEE FIGURE # 2. IF THE TANK IS LOWERED MORE THAN 4-5 INCHES, OR IF THE TANK IS LOWERED STRAIGHT DOWN WITHOUT ALSO MOVING IT A FEW INCHES REARWARD, THE FUEL DELIVERY MODULE PORTS COULD BE BENT.
7. DISCONNECT THE FUEL SUPPLY LINE FITTING AT THE FUEL DELIVERY MODULE (REFERENCE APPENDIX I OF INSTRUCTION SHEET 8117 OR 8118 IN KIT CC OR DD FOR REMOVAL PROCEDURE). SEE FIGURE # 2 ABOVE. NOTE: FOR PURPOSES OF CLARITY, THE FUEL LINE SAFETY CLIPS ARE NOT SHOWN - THEY ARE REQUIRED.
8. WITH THE FUEL SUPPLY LINE STILL DISCONNECTED, CAREFULLY MOVE THE FUEL TANK BACK INTO POSITION BY LIFTING THE FRONT OF THE TANK FIRST. BE CAREFUL NOT TO KINK THE FUEL LINES AT THE FRONT OF THE TANK. SEE FIGURE # 3. POSITION FUEL TANK SUPPORTS AND INSTALL ATTACHING BOLTS AND NUTS. TIGHTEN TO 37-50 N-m (27-37 FT.LB.). FOR ADDITIONAL INFORMATION, SEE TSB 91-23-10.
9. RECONNECT THE FUEL FILLER HOSE TO THE FUEL TANK AND TIGHTEN CLAMP TO 3-4 N-m (25-35 IN.LB) OR, IF THE FILLER NECK WAS REMOVED AT THE BODY SHEET METAL, REATTACH WITH THE THREE SCREWS.
10. INSTALL CHECK VALVE CONNECTOR TO THE FUEL SUPPLY LINE FIRST (NOT TO THE FUEL DELIVERY MODULE). NOTE: MAKE SURE TO INSTALL THE SAFETY CLIP CONNECTING THE FUEL LINE AND THE CHECK VALVE AND TO POSITION IT SO THE LONG LEGS OF THE CLIP WILL BE HORIZONTAL TO THE GROUND WHEN ATTACHED TO THE FUEL DELIVERY MODULE IN STEP # 12.
11. PRE-POSITION THE SECOND SAFETY CLIP ON THE OTHER END OF THE CHECK VALVE CONNECTOR (IF NOT ALREADY PRE-POSITIONED - SEE NOTE IN STEP # 10).
12. CONNECT THE FUEL SUPPLY LINE AND CHECK VALVE CONNECTOR ASSEMBLY (WITH SAFETY CLIP PRE-POSITIONED) TO THE FUEL DELIVERY MODULE BY INSERTING THROUGH THE SPACE BETWEEN THE FRAME CROSSMEMBER AND THE PICKUP BOX BED SUPPORT. SEE FIGURE # 4 AND # 5 BELOW. DO NOT ATTACH UNTIL A SAFETY CLIP IS PRE-POSITIONED ON THE OPEN END OF THE CHECK VALVE CONNECTOR AND THE OTHER SAFETY CLIP IS ATTACHED BETWEEN THE CHECK VALVE AND THE FUEL SUPPLY LINE. (REFERENCE APPENDIX I OF INSTRUCTION SHEET 8117 OR 8118 IN KIT CC OR DD FOR INSTALLATION PROCEDURE). AFTER THE FUEL LINE AND CHECK VALVE CONNECTOR ARE ATTACHED TO THE FUEL DELIVERY MODULE, USE A LARGE FIAT BLADE SCREWDRIVER TO FULLY SEAT THE SAFETY CLIP ONTO THE SUPPLY LINE OF THE FUEL DELIVERY MODULE AND THE CHECK VALVE. MAKE SURE TO POSITION THE SAFETY CLIP SO THE LEGS OF THE CLIP WILL BE HORIZONTAL TO THE GROUND WHEN ATTACHED TO THE FUEL DELIVERY MODULE. BOTH SAFETY CLIPS MUST BE INSTALLED.
13. REMOVE JACK AND REPOSITION SPARE TIRE.
14. CONTINUE WITH INSTALLATION OF FRONT FUEL TANK CHECK VALVE AND FUEL PRESSURE REGULATOR PER THE INSTRUCTION SHEET PACKED WITH KITS CC AND DD.
SECTION II - REVISED KITS TO REPLACE KITS EE, FF. GG, AND HH:
EFFECTIVE IMMEDIATELY, KITS EE, FF, GG, AND HH ARE CANCELLED (PART NUMBERS F4PZ-9155-E, -F, -G, AND -H).
PARTS PRICES AND APPLICATIONS FOR KITS JJ AND KK:
LABOR ALLOWANCES FOR KITS JJ AND KK:
Note
- Add 0.1 hour Administrative Allowance to the total repair time.
- Add additional 0.1 Hour if truck is over 8,500 lbs. GVWR and equipped with a 5.8L engine.
SECTION III - RECALL 93S68 HELPFUL HINTS
1. Always be certain you have the correct kit. Each kit is different and has specific vehicle applications. DO NOT MIX COMPONENTS FROM DIFFERENT KITS.
2. Kits AA, CC, and JJ may contain a new design fuel pressure regulator gasket which appears to have 1/3 of the end cut off. This is normal.
3. When disconnecting Aeroquip fuel line connectors on 1992/1993 models (Kits CC and DD), it may be difficult to completely disengage the locking clip in the connector unless the connector is first pushed onto the male end of the line as far as possible.
4. If the locking clip in the Aeroquip fuel line connector is damaged in the removal of a 1992/1993 fuel line assembly, a new locking clip (basic part number 9B307) must be installed in the connector. Do not attempt to repair the damaged locking clip.
5. When servicing the aft-axle tank on the 1990/1991 models (Kits AA and BB), reinstallation of the fuel line after the check valve is installed on the supply side of the fuel delivery module may be difficult due to limited clearance to the crossmember. Installation may be easier if the installation sequence defined in the kit instructions for the aft-axle tank is reversed and the check valve is connected to the fuel line BEFORE attaching to the fuel delivery module. If necessary, the fuel line hold-down clip on the crossmember may be temporarily opened to allow the end of the supply line to be moved to the forward side of the crossmember for easier access. Reinstall all lines in the clip when completed.
6. If a plastic elbow connector is damaged on a 1990/1991 fuel line assembly, the line can be repaired by either of two methods:
a) The damaged connector may be cut off and a replacement connector (part number N806797-S190) installed using Rotunda Tool 134-00001.
OR
b) the damaged connector and a section of fuel line may be cut off and a new section of fuel line including a connector (basic part number 9291) may be spliced onto the existing fuel line using Rotunda Tool 134-000001. Use connector N806119-S to perform the splice. Trim the lines to the desired length before splicing.
7. Special precautions must be taken to prevent kinked fuel lines as pointed out in the kit instructions. BE SURE TO READ AND FAMILIARIZE YOURSELF WITH THESE PRECAUTIONS. For additional information, Technical Service Bulletin 91-23-10 also addresses the issue of kinked fuel lines.
8. When reinstalling fuel lines after installation of the check valve connector from the kit, be sure that BOTH safety clips are properly reinstalled (one clip between check valve connector and the fuel delivery module; second clip between the fuel supply line and the check valve connector).
9. In the event that a fuel line is inadvertently damaged during kit installation, repair using parts, tools, and procedures found under Group 10 in the appropriate Shop Manual and Technical Service Bulletin 92-12-16.