Campaign - Fuel Filler Door Modification
NUMBER K037(ISSUE 1)
MODEL XF
DATE 14 APR 2009
THIS SERVICE ACTION IS VALID FOR TWO YEARS AND WILL EXPIRE 30 APRIL 2011
SECTION: 501
SERVICE ACTION K037: Fuel Filler Door Intermittent Operation
AFFECTED VEHICLE RANGE
CONDITION SUMMARY:
Situation:
A number of 2009 model year XF vehicles' fuel filler door hinge arms may have been manufactured away from process and, in some cases, the fuel filler door is intermittently difficult to open or cannot be opened at all.
Action:
Dealers are required to update all affected vehicles within their control and withhold them from retail delivery pending completion of the rework actions detailed in this bulletin. Owners will be notified of this Service Action with an Owner Notification Letter (refer to Service Administration Bulletin 3-254CAN / 3-254USA for details), beginning April 2009. Affected vehicles in the hands of owners should be repaired at the next available opportunity. At the time of customer appointment, ensure that all outstanding service campaigns for each individual vehicle are identified and allocate sufficient time and resources to complete all campaigns. Refer to the Repair Procedure outlined below to replace the fuel filler door hinge arm and add a spring.
PARTS
TOOLS
WARRANTY
REPAIR PROCEDURE
WARNING:
Place the vehicle in a well ventilated, quarantined area and arrange 'No Smoking / Petrol Fumes' signs about the vehicle.
WARNING:
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
NOTE:
Do not remove any material from the moulded button on the end of the hinge arm or the hinge arm striker; the button is designed to keep the fuel filler door aligned within the body aperture and the striker is to the latest condition.
REPLACE FUEL FILLER DOOR HINGE AND SPRING
1. Open the fuel filler door.
2. Remove the fuel filler cap tether clip from the hinge arm. (Figure 1)
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows: GTR Home > NAS > X250 - XF > Service Information > 2009 > Workshop Manual > 5: Body and Paint > 501: Body and Paint > 501-03: Body Closures
3. Refer to Workshop Manual (GTR) section 501-03: Body Closures to remove the fuel filler door.
4. Remove the hinge arm.
^ With hinge arm fully open (90° to body) insert a medium-sized flat bladed screwdriver between top face of hinge arm and bowl pushing towards the front of vehicle approximately 6cm (2.4in), rotate screwdriver clockwise to disengage the upper hinge arm pivot from the fuel bowl assembly.
^ While still holding the hinge arm, remove the screwdriver and lift the arm upwards to fully disengage the arm from the bowl. Excessive force should not be required. (Figure 2)
5. Remove the fuel filler cap and insert the service tool (JLM21856) into the front pocket of the fuel filler bowl.
6. Install the fuel filler cap.
7. Engage the forward vertical leg of the spring through the slot in the tool. (Figure 3)
8. Push the service tool fully forward and inboard into the bowl pocket.
9. With service tool still fully engaged forward and inboard into the bowl pocket and spring engaged, push the replacement hinge / spring assembly forwards using firm pressure until an audible 'click' is heard indicating hinge pivot engagement.
10. Remove the fuel filler cap and then remove the service tool.
11. Refit the fuel filler cap, and carefully check hinge arm and spring are fully engaged, check operation. (Figure 4)
12. Install the fuel filler cap tether clip.
13. Refer to Workshop Manual (GTR) section 501-03: Body Closures to install the fuel filler door.
Note:
The fuel filler door will cease operation after three successive attempts to open. If this occurs, normal operation will resume after one minute.
14. Verify fuel filler door operation.