Fuel Tube/Connector - Service Procedure
84ford14Article No. 84-11-8
FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT FITTINGS
FORD ALL 1982-84 VEHICLES WITH CFI/EFI ENGINES
LINCOLN-MERCURY ALL 1982-84 VEHICLES WITH CFI/EFI ENGINES
In the event that services are required on 1982-84 vehicles equipped with nylon fuel tubes and/or CFI and EFI fuel systems, service parts and service procedures are being released. The following service procedures have been developed and must be adhered to:
MAJOR SERVICE OPERATIONS
Fuel Lines Vehicles equipped with nylon fuel tubes and push connect fittings have three types of service that can be performed to the fuel lines; replacing nylon tubing (splicing nylon to nylon), replacing push connector and replacing damaged push connect tube end. These three methods follow:
Splicing Nylon to Nylon
1. Relieve fuel system pressure as outlined in the 1983 Car Shop Manual - Powertrain Section 24-50. Read cautionary note prior to relieving pressurized fuel system.
2. Cut out damaged section of tubing and retain as a guide.
3. Cut a section of nylon service tubing (type 11 or 12 available in 1/4 and 5/16 inch sizes) to the same length as the damaged section of tubing.
FIGURE 5:
FIGURE 6:
4. Select the proper (1/4 or 5/16-inch) barbed connectors for completing the splice. Two connectors are required for each splice (Figure 6).
NOTE: To make hand insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon. The 5/16-inch barbed connector is used for splicing 5/16-inch non-CFI and 5/16 CFI tubing. Refer to Figure 5 for all splicing service combinations.
5. Install the barbed connectors into each end of the replacement tubing using boiling water as outlined.
6. Install clips onto any tubes which might be difficult to access once the final splices are completed.
a. Install four (4) Keystone clamps (part no. 377931) onto the original nylon tubing (loosely) before beginning Step 7.
FIGURE 6:
7. Complete the splice of the replacement nylon to the original nylon tubing at both ends. (Use the boiling water method mentioned previously, to get the required number of barbs engaged, as shown in Figure 6.).
a. Tighten the clamps in the locations shown in Figure 6.
8. Install any remaining clips which were removed for this service and check that the tubes are secure in the original clips.
9. Start engine and check for leaks.
Replacing Damaged Push Connectors
1. Relieve fuel system pressure as outlined in the 1983 Car Shop Manual - Powertrain Section 24-50. Read cautionary note prior to relieving pressurized fuel system.
NOTE: Damaged push connectors must be discarded and replaced with new push connectors. If only the retaining clip is damaged, replace the clip.
2. Disconnect the damaged push connector. Be sure to bend the shipping tab to the side before removing retaining clip.
FIGURE 5:
3. Select the proper size replacement push connector and nylon tube assembly (Figure 5).
4. Cut out a section of the original nylon tube to the same length as the nylon tube attached to the new push connector.
FIGURE 6:
5. Install proper barbed connector into the replacement nylon assembly.
NOTE: To make hand insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon. The 5/16" non-CFI and 5/16" CFI tubing. Refer to Figure 6 for all splicing service combinations.
a. Put two (2) Keystone clamps (part no. 377931) onto the original nylon tubing (loosely) before beginning Step 6.
6. Complete the splice by connecting the barbed connector to the original nylon. Refer to Figure 6 for the proper barb insertion.
a. Tighten the clamps in the locations shown in Figure 6.
7. Connect the new connector assembly to the steel tube end. Pull back on the connection to insure that the fittings have completely engaged and are locked.
8. Check that the underbody clips are properly securing the fuel tubes.
9. Start engine and check for fuel leaks.
Replacing Damaged Steel Push Connect Tube Ends
1. Relieve fuel system pressure as outlined in the 1983 Car Shop Manual - Powertrain Section 24-50. Read cautionary note prior to relieving pressurized fuel systems.
FIGURE 5:
2. Using a tube cutter, remove the damaged push connect tube end at a convenient distance from the end.
NOTE: Allow for adequate room to tighten a union with a wrench at this location.
3. Choose a proper replacement push connect tube end (Figure 5).
4. If required, form a new tube end to the same shape as the damaged tube end which was removed.
5. Select the proper size union (Figure 5) and attach the new steel tube end to the original tube.
6. Clean off the steel tube end and insert the push connector onto the tube. (A new retainer clip is recommended.) Pull back on the connection to insure that fittings have completely engaged and are locked.
7. Check that the underbody clips are properly securing the fuel tubes.
8. Start engine and check for fuel leaks.
Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield.
PART NUMBER PART NAME CLASS
389351-S43 Union-5/16 S
390080-S43 Union-1/4 S
N803430-S Union-1/4 S
N803431-S Union-5/16 S
E3FZ-9291-B Tube-1/4 Straight C
E3FZ-9291-C Tube-5/16 Straight C
E3FZ-9291-D Tube-5/16 Elbow C
E3FZ-9291-E Tube-5/16 Steel C
E3FZ-9291-F Tube-1/4 Steel C
E3FZ-9291-G Tube-1/4 Bulk C
E3FZ-9291-H Tube-5/16 Bulk C
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: 9999A
TIME: 0.3 Hr. DLR. CODING: Basic Part No. 9312 Code: 73