Fuel System - Difficult or Slow Filling Fuel Tank
Article No.94-14-11
07/13/94
FUEL SYSTEM - DIFFICULT OR SLOW FILLING FUEL TANKS - F-SERIES CHASSIS CAB VEHICLES
LIGHT TRUCK:
1987-94 F-250, F-350
This TSB is being republished in its entirety to correct a misprint in this article.
ISSUE:
Some trucks may experience a difficult or slow fuel fill rate. This may occur because of misassembled fuel fill pipes or the current fill pipe does not handle large nozzles and high flow rates available at larger fuel stations and truck stops.
ACTION:
Replace fuel fill pipes. In diesel applications, the external vent hose replaces the internal vent hose and the fill hose is larger. In gasoline applications, pre-assembled hoses prevent misassembly and the hoses are larger. Refer to the following procedure for service details.
DIESEL APPLICATIONS
1. Disconnect the fill housing/retainer from the body of the vehicle.
a. Disconnect the fuel fill hose from the tank.
b. Lower the tank if there is not enough room between the tank and the vehicle body. Refer to the appropriate Service Manual, Section 10-01, for service details.
2. Remove the vapor valve and vapor valve grommet from the tank. Unclip and remove the small hose and cap from the frame.
3. Install a new grommet (E8UZ-9BO76-A) and install a new fill vent valve in the tank.
NOTE:
THE NEW FILL SYSTEM MAY HAVE TO BE SHORTENED TO FIT THE VEHICLE.
4. To shorten the hoses, proceed as follows:
a. Disconnect hoses from the steel pipe assembly and cut to the required length at the outboard end.
b. Trim both the vent (small) and fill (large) hoses by the same amount. This should allow sufficient length for the vent hose to reach the new vent valve. The fill hose should be the same length as the old hose, but do not allow excessive length in either the fill or vent hoses that might form sink traps.
CAUTION:
DO NOT CUT THE INBOARD END OF HOSE BECAUSE IT IS PREMOLDED TO FIT THE TANK.
5. Install the new housing, with the upper pipe assembly attached, to the body of the vehicle.
a. Connect the end of the fill hose to the tank and the end of the vent hose to the valve.
b. Tighten the fill hose clamp to 3.2 N-m +/- .5 N-m (28.3 +/- 4.4 lb.in.) and the vent hose clamp to 3.2 N-m +/- .5 N-m (28.3 +/- 4.4 lb.in.).
CAUTION:
BE SURE PROTECTIVE SLEEVES ARE OVER THE FRAME RAIL.
c. Install the outboard ends of the hoses to the upper pipe.
d. Tighten the fill hose clamp to 3.2 N-m +/- .5 N-m (28.3 +/- 4.4 lb.in.) and the vent hose clamp to 3.2 N-m +/- .5 N-m (28.3 +/- 4.4 lb.in.). Refer to Figures 1 and 2.
6. Attach the ground wire to the frame crossmember by sliding the clip over the edge of the crossmember with the wire lead pointing down.
GASOLINE APPLICATIONS
1. Disconnect the fill housing/retainer from the body of the vehicle.
a. Disconnect the fuel fill hose from the tank.
b. Lower the tank if there is not enough room between the tank and the vehicle body. Refer to the appropriate Service Manual, Section 10-01, for service details.
NOTE:
NEW HOSES MAY HAVE TO BE SHORTENED TO FIT THE VEHICLE.
2. To shorten the hoses, proceed as follows:
a. Disconnect the outer hoses from the steel pipe assembly and slide it away to provide access to the inner (fill) hose clamp.
b. Disconnect the inner hose from the inner pipe and discard the pinch clamp.
c. Trim both the inner and the outer hoses by the same amount to achieve desired overall length. Do not allow excessive length that might cause sink traps to form.
CAUTION:
DO NOT CUT THE INBOARD END OF HOSE BECAUSE IT IS PREMOLDED TO FIT THE TANK.
3. Reinstall the inner hose on the pipe using a new pinch clamp (N808877-S).
a. Slide and re-engage the outer hose to the pipe.
b. Tighten the clamp to 3.2 N-m +/- .5 N-m (28.3 +/- 4.4 lb.in.).
4. Install the new housing, with pipe and hoses attached, to the body of the vehicle.
a. Install the other end to the tank.
b. Tighten the clamp to 3.2 N-m +/- .5 N-m (28.3 +/- 4.4 lb.in.).
CAUTION:
BE SURE THE PROTECTIVE SLEEVE IS POSITIONED OVER THE FRAME RAIL.
5. Attach the ground wire to the frame crossmember by sliding the clip over the edge of the crossmember with the wire lead pointing down.
Parts Block
OTHER APPLICABLE ARTICLES: 91-17-10
SUPERSEDES: 94-11-17
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Models, Emissions Warranty Coverage For All Models
OPERATION DESCRIPTION TIME
941411A Replace Fill Housing 0.6 Hr.
Assembly, Vapor Vent And
Grommet - One Tank -
Diesel Engine Applications
941411B Replace Fill Housing 1.2 Hrs.
Assembly, Vapor Vent And
Grommet - Both Tanks -
Diesel Engine Applications
941411C Replace Fill Housing 0.6 Hr.
Assembly - One Tank -
Gas Engine Applications
941411D Replace Fill Housing 1.2 Hrs.
Assembly - Both Tanks -
Gas Engine Applications
941411E Additional Time To 0.5 Hr.
Reposition One Tank If
Required For Access
941411F Additional Time To 1.0 Hr.
Reposition Both Tanks If
Required For Access
DEALER CODING
BASIC PART NO. CONDITION CODE
9034 42
OASIS CODES: 404000