Fill Valve Mounting Cup Replacement

TOOLS REQUIRED
J 41416 Ultrasonic Leak Detector

REMOVAL PROCEDURE

CAUTION:
^ Refer to Compressed Natural Gas (CNG) Flammability Caution in Service Precautions.
^ Refer to Compressed Natural Gas (CNG) Fuel Pressure Relief Caution in Service Precautions.




1. Relieve the CNG fuel system pressure. Refer to the Fuel Pressure Relief Procedure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the fill line (2) from the fill valve at the fill valve fitting (3).




4. Remove the fill valve cover (2) from the fill valve cup (1).
5. Remove the fill valve cover tether (3) hold down pin (4) from the fill valve cup (1).




6. Remove the fill valve jam nut (2).




7. Remove the three bolts (2) that secure the two mounting cup halves together.
8. Remove the bolt (3) that secures the lower mounting cup (1) to the bumper.
9. Separate and remove the fill valve and the mounting cup assembly from the vehicle.

INSTALLATION PROCEDURE




1. Place the lower mounting cup (3) against the vehicle bumper (1).

NOTE: Refer to Fastener Notice in Service Precautions.




2. Install the lower cup (1) mounting bolt (3) rotating the cup so that the drain hole is on the bottom.

Tighten
Tighten the bolt to 12 N.m (106 lb in).

3. Install the fill valve into the mounting cup.




4. Place the upper mounting cup (2) through the bumper (1) aligning the slot with the groove.




5. Install the upper mounting cup bolts (2).

Tighten
Tighten the bolts to 12 N.m (106 lb in).




6. Install the fill valve jam nut (2).

Tighten
Tighten the nut to 28 N.m (21 lb ft).

CAUTION: Refer to Compressed Natural Gas (CNG) O-Ring Caution in Service Precautions.




7. Install the fill line fitting (3) to the fill valve using a new O-ring. Lubricate the O-ring with petroleum jelly or equivalent before installation.

Tighten
Tighten the fuel line fitting to 37 N.m (27 lb ft).

8. Secure the fill valve cover tether (3) to the mounting cup (1) using the tether hold down pin.
9. Connect the negative battery cable.
10. Prime the CNG fuel system by cycling the ignition ON and OFF several times.
11. Start the engine and use the J 41416 in order to inspect for CNG fuel system leaks at each serviced fitting.