Fuel Tank - Removal and Installation Correction
89Ford12
FUEL SYSTEM - FUEL TANKS AND LINES - FUEL
TANK REMOVAL AND INSTALLATION PROCEDURES
- SHOP MANUAL CORRECTION
Article No. 89-5A-16
FORD: 1989 THUNDERBIRD
LINCOLN-MERCURY: 1989 COUGAR
ISSUE: The fuel tank removal and installation procedures on pages 24-50-7 and 24-50-8 of the 1989 Thunderbird/ Cougar Car Shop Manual, have been revised. The new information includes an added fuel tank retainer, caution note, and torque specifications.
ACTION: If service is required, refer to the information on this TSB. This information should be inserted in your 1989 Thunderbird/Cougar Shop Manual, pages 24-50-7 and 24-50-8.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"
OASIS CODES: 680000
1989
24-50-6 Fuel Tanks and Lines
REMOVAL AND INSTALLATION
Most components of the standard fuel system are serviced by a simple nut, bolt or screw part for removal and installation. Fuel lines are attached to the vehicle underbody by clips and retainers using plastic push pins. If push pins are removed they must be replaced with new pins. Refer to individual system illustrations for specific part references.
Fuel System Pressure Relief
EFI Engines
WARNING: FUEL SUPPLY LINES ON ALL VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN.
Fuel Tank Removal
1. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe. For some models, the use of a small diameter hose might be necessary because of special components inside the fuel filler pipe. Use a 6.35 mm (1/4- inch) fuel hose. Vehicles with fuel injected engines have reservoirs inside the fuel tank to maintain fuel near the fuel pickup during vehicle cornering maneuvers and under low fuel operating conditions. These reservoirs could block siphon tubes or hoses from reaching the bottom of the fuel tank. This situation can be overcome with a few repeated attempts using different hose orientations.
2. Remove the exhaust pipe and exhaust shield.
3. Disconnect fuel hoses and tubes. Disconnect one end of the vapor crossover hose at the rear over the driveshaft.
NOTE: The plastic fuel tube connections are on top of the fuel tank and are inaccessible. In these cases, the fuel lines must be disconnected with the tank partially removed from the vehicle.
4. Place a safety support under the tank. Remove the bolts from the fuel tank straps. Take care not to deform the fuel tank, fuel tank support or straps to avoid affecting fuel tank capacity and/ or fuel pick-up.
5. Partially remove the tank and disconnect the fuel lines and electrical connector from the fuel gauge sender, if required. Refer to Push Connect Fitting Removal, if so equipped.
6. Remove tank from the vehicle. For electric fuel pump removal and installation refer to Section 24-35.
1989
24-50-8 Fuel Tanks and Lines
REMOVAL AND INSTALLATION (Continued)
Installation
1. Before proceeding, check the following items:
a. Leak check the sender unit. If necessary, tighten with Fuel Tank Sender Wrench T74P-9275-A or equivalent.
b. Ensure fuel vapor separator valve is installed completely on the tank top.
c. Make all required fuel line, fuel return line, vapor vent and electrical connections which will be inaccessible after the tank is installed.
d. Replace or install all body mounted fuel tank shields.
2. Place the fuel tank in its proper position in the vehicle. Lubricate the fuel filler pipe hose with water base tire mounting lubricant. Install the tank onto the filler pipe hose then bring the tank into final position.
3. Bring fuel tank straps around the tank and start the attaching nut or bolt. Align tank with the straps and driveshaft.
4. Check the hoses and wiring mounted on the tank top to ensure they are correctly routed and will not be pinched between the tank and body or driveshaft.
CAUTION: Ensure the fuel vent hose is positioned above the vent retainer and not contacting the driveshaft.
5. Tighten the fuel tank strap attaching nuts or bolts to specification. (28-40 N-m).
6. Reconnect the fuel hoses and lines which were disconnected. Ensure that the fuel supply, fuel return, (if present) and vapor vent connections are made correctly. Trace the various lines to the engine and refer to the applicable system illustrations to ensure the proper lines are connected.
7. Install exhaust pipe shield and exhaust pipe.
CAUTION: Ensure that fuel tank shields are installed and are positioned correctly on the tank. Refer to the applicable system illustration.
8. Replace fuel drained from the tank.
9. Check all connections for leaks.
Fuel Tank Straps
Removal and Installation
Straps may be removed and/or replaced without removing the tank, if each strap is removed and installed one at a time and a support is provided under the tank, or by following the procedure for fuel tank removal.
CAUTION: Ensure that fuel tank shields are installed and are positioned correctly on the tank. Refer to the applicable system illustration. Install all fuel tank shields.
WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. REFER TO FUEL SYSTEM PRESSURE RELIEF.
Nylon Push Connect Fittings
Disconnect all push connect fittings from components (sender, filter) prior to component removal. The push connect fittings that connect flexible fuel lines to the fuel tank sender cannot be disconnected until the tank is partially lowered just before removing the fuel tank completely.
5/16;Inch or 3/8-Inch Fittings (Hairpin Clip)
Removal
1. Inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly.
2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube.
3. Remove "hairpin"-type clip from fitting by first bending and breaking the shipping tab. Next, (using hands only) spread the two slip legs about 3.2 mm (1/8-inch) each to disengage the body and push the legs into the fitting. Complete removal is accomplished by lightly pulling from the triangular end of the clip and working it clear of the tube and fitting.
CAUTION: Do not use any tools.
4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube.
NOTE: On 90 degree elbow connector excessive side loading could break the connector body.
5. After disassembly inspect and clean tube end sealing surface. Tube end should be free of scratches and corrosion as they result in a path for fuel leakage. Inspect inside of fitting for any internal parts such as O-ring and spacer that may have been dislodged from the fitting. Replace damaged connector, do not repair it.
1989
24-50-9 Fuel Tanks and Lines
REMOVAL AND INSTALLATION (Continued)
Installation
1. Install a new connector if connector was found to be damaged. Install the new clip, insert clip into any two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs of "hairpin" clip locked on outside of body). Piloting with an index finger is necessary.
2. Before installing fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to ensure it is free of dirt and/or obstructions.
3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the tube end. When the fitting is engaged, a definite click will be heard. Pull on fitting to ensure it is fully engaged.
Spring Lock Coupling
The spring lock coupling is a fuel line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. As a redundant locking feature, a horseshoe shaped retaining clip is incorporated to improve the retaining reliability of the spring lock coupling.
Removal
1. Release fuel system pressure. A pressure relief (Schrader) valve on the fuel rail assembly is provided for this procedure.
2. Remove retaining clip from spring lock coupling by hand only. Do not use any sharp tool or screwdriver as it may damage the spring lock coupling.
3. Twist fitting to free it from any adhesion at the O-ring seals.
4. Fit Spring Lock Coupling Tool D87L-9280-A (3/8 inch) or D87L-9280-B (1/2 inch) or equivalent to coupling.
5. Close tool and push into open side of cage to expand garter spring and release female fitting.
6. After garter spring is expanded, pull fittings apart.
7. Remove tool from disconnected coupling.
Installation
1. Ensure that garter spring is in cage of male fitting. If garter spring is missing, install a new spring by pushing it into cage opening. If garter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring.
2. Clean all dirt or foreign material from both pieces of coupling.
3. Replace missing or damaged O-rings. Use only O-rings listed in Spring Lock Coupling illustration.
WARNING: USE ONLY THE SPECIFIED O-RINGS AS THEY ARE MADE OF A SPECIAL MATERIAL. THE USE OF ANY O-RING OTHER THAN THE SPECIFIED O-RING MAY ALLOW THE CONNECTION TO LEAK INTERMITTENTLY DURING VEHICLE OPERATION. Lubricate male fitting and O-rings and inside of female fitting with clean engine oil meeting Ford Specification ESE-M2C39-F or equivalent.
4. Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting.
5. Ensure coupling engagement by pulling on fitting and visually checking to ensure garter spring is over flared end of female fitting.
6. Position retaining clip over metal portion of spring lock coupling. Firmly push retaining clip onto spring lock coupling. Ensure that horseshoe portion of clip is over the coupling. Do not install retaining clip over rubber fuel line.
NOTE: All vehicles require the large "black" clip to be installed on the supply side fuel line and the small "gray" clip to be installed on the return side fuel line.