Attachment III - Technical Information

FUEL LINE MODIFICATION AND/OR REPLACEMENT

AFFECTED VEHICLES:
1992-1993 THUNDERBIRD AND COUGAR

INSPECTION

1. Raise and support vehicle.





2. Position hydraulic jack under fuel tank. Refer to Figure 1.





3. Remove right fuel tank strap front retaining bolt. Refer to Figure 2.

4. Swing down the fuel tank strap. See Figure 2.

5. Remove clamp from fuel filler hose to fuel tank.





6. Remove pushpins and bolt retaining fuel lines to the underbody. See Figure 3.

7. Carefully lower right side of fuel tank. While lowering fuel tank, disconnect fuel filler hose from fuel tank.





8. Locate area of fuel lines to be inspected for fuel leakage. See Figure 4.

9.

^ If fuel leakage is present, order fuel line F4SZ-9S278-A, then proceed to "Fuel Line Assembly Replace."

^ If fuel leakage is not present, proceed to "Convolute Installation."

CONVOLUTE INSTALLATION

NOTE:
When installing convolute, the slit must face the fuel tank, away from the floor pan.





1. Install convolute over all three (3) fuel lines in area shown in Figure 5.

2. Install tie straps over convolute. See Figure 5.

3. Carefully raise fuel tank to installed position. While raising tank, connect fuel filler hose to fuel tank.

4. Tighten fuel filler hose clamp to 1.8-2.6 Nm (16-23 lb/in).

5. Install pushpins and bolt retaining fuel lines to underbody.

6. Lower vehicle.

7. Start and run vehicle.

8. Check fuel filler neck jumper hose for leaks.





FUEL LINE ASSEMBLY REPLACE

1. Disconnect fuel supply, return and vent lines from side of underbody and top of fuel tank.

2. Remove fuel lines from the vehicle.

3. Install new fuel line assembly and connect line to top of fuel tank and underbody connections.

4. Carefully raise fuel tank to installed position. While raising tank, connect fuel filler hose to fuel tank.

5. Install fuel tank strap. Tighten retaining bolt to 29-41 Nm (22-30 lb/ft).

6. Tighten fuel filler hose clamp to 1.8-2.6 Nm (16-23 lb/in).

7. Install pushpins and bolt retaining fuel lines to underbody.

8. Lower vehicle.

9. Start and run vehicle.

10. Check fuel filler neck jumper hose for leaks.