Fuel Tank Pipe Seals - Replacement Procedure
05.1-03DATE:
8/95
Sedan Range
MODEL:
1995 MY
Sedan (4.0L) Range
VIN:
720001-ON
Fuel Tank Pipe Seals - Replacement Procedure
ISSUE:
Replacement seals for the fuel supply or return pipe connections at the fuel tank are supplied as a kit. The seal kit (part number EBC 9606) includes the required seals and spacers mounted on a disposable "stuffer pin." The "stuffer pin" is used to insert the seals into the fuel pipe connector bore.
ACTION:
To replace the seals for the fuel supply or return pipe connections at the fuel tank, follow the procedure described below.
NOTE:
It is not required to replace the seals each time the a fuel pipe is disconnected. Change the fuel tank supply or return pipe connection seals in the event of fuel leaks only.
FUEL TANK PIPE SEAL REPLACEMENT PROCEDURE
1. Depressurize and drain the fuel tank following the instructions in the applicable service manual.
2. Thoroughly clean the fuel tank pipe, tank connector and the surrounding area.
3. Place tool JD 203 around the fuel pipe as shown in Illustration 2. With a twisting motion, slide the tool upward along the pipe and into the connector. The tool will release retainer legs from the fuel pipe.
4. Pull the fuel pipe and the tool, together, out of the tank connector.
5. With needle nose pliers, bend the retainer legs of the tank connector inward to release the retainer from the tank connector bore. Pull the retainer out of the tank.
6. With a plastic or soft metal hook, pull the two spacers and seals out of the connector bore.
NOTE:
Sharp tools may damage the bore and cause leaks.
7. Clean and inspect the tank connector bore.
8. Remove the seal kit assembly protector, check the position of the seals and spacers and lubricate them liberally with clean engine oil (Illustration 3).
9. Insert the assembly fully into the tank connector bore. Check that the retainer legs are seated behind the connector lip. Slide the "stuffer pin" out of the assembly and check the position of the seals and spacers in the bore.
NOTE:
The "stuffer pin" should slide out easily; if not the retainer legs are not seated, or the assembly or connector bore is damaged.
10. Clean the fuel pipe end and lubricate it with clean engine oil.
11. Push the pipe into the connector until its collar seats behind the retainer legs.
NOTE:
If the pipe does not slide in easily, check the seal assembly or bore for damage.
12. Refill the tank, pressurize the system and check for fuel leaks.
PARTS INFORMATION:
DESCRIPTION PART NO. QTY
Stuffer pin EBC9606 1
WARRANTY INFORMATION
Use warranty code applicable to fault Refer to Warranty Codes & Repair Operation Times Manual.