Supplement: Attachment III - Technical Information
FUEL VENT HOSE REPLACEMENTAFFECTED VEHICLES:
CERTAIN 1996 CONTOUR AND MYSTIQUE VEHICLES
OVERVIEW
This repair involves lowering the rear sub-frame and replacing the fuel vent hose. Two things are critical to this repair.
1. The use of "draw bolts" when lowering and raising the rear sub-frame.
2. Using scribe marks around the sub-frame mounting bolts before lowering the sub-frame so that proper alignment is ensured when the sub-frame is bolted back into position.
In order to perform this repair properly, the instructions that follow must be carefully observed.
FUEL VENT HOSE REPLACEMENT
1. Raise and support the vehicle.
NOTE:
Do not disengage the exhaust hanger at the rear sub-frame. The exhaust will be lowered with the rear sub-frame.
2. Disengage the exhaust hangers at the following locations:
At the rear of the vehicle behind the muffler assembly.
At the left inner rocker panel in front of the rear sub-frame.
WARNING
DO NOT POSITION THE ADJUSTABLE JACK STAND IN CONTACT WITH THE REAR SUB-FRAME. THE SUB-FRAME IS UNDER A LOAD FROM THE REAR STRUTS, AND MUST BE LOWERED ONTO THE ADJUSTABLE JACK STAND TO AVOID SUDDEN SHIFTING OF THE VEHICLE ON THE HOIST.
3. Position an adjustable jack stand approximately 25 mm (1 inch) below the center of the rear sub-frame. See Figure 1.
CAUTION
The use of bolts longer than 70 mm (2-314 inches) will result in damage to the vehicle floorpan.
4. Obtain locally two (2) bolts (12 mm x 1.75) between 58 mm and 70 mm (2-9/32 inches and 2-3/4 inches) in length and two (2) flat washers. These bolts will be used as draw bolts during the lowering and raising of the rear sub-frame.
NOTE:
Marking the location of the sub-frame mounting bolts is necessary for proper alignment of the sub-frame during installation.
5. Scribe the sub-frame around the perimeter of the four (4) mounting bolts.
6. One at a time, replace the two (2) rear retaining bolts of the rear sub-frame with the two (2) draw bolts and washers. See Figure 1.
7. Remove the two (2) front retaining bolts from the rear sub-frame.
8. Alternately loosen the two (2) draw bolts in 6 mm (1/4 inch) increments to lower the rear sub-frame onto the adjustable jack stand. Then, completely remove the draw bolts and washers.
9. Lower the adjustable jack stand and rear sub-frame 75 mm (3 inches) to access the fuel vent hose. See Figure 2.
10. Replace the fuel vent hose as follows:
Loosen the two (2) clamps, then remove the hose.
Install the replacement hose with the original clamps. Tighten the clamps securely.
11. Install the Rear Sub-Frame Alignment Pin Set T94P-2100-AH into the alignment holes of the rear sub-frame. See Figure 3.
WARNING
RAISING THE REAR SUB-FRAME BEYOND THE POINT WHERE THE SUB-FRAME CONTACTS THE REAR STRUTS MAY RESULT IN SUDDEN SHIFTING OF THE VEHICLE ON THE HOIST.
12. Raise the adjustable jack stand and rear sub-frame until the rear struts contact the sub-frame. See figure 3.
NOTE:
Guide the alignment pins into the body as the rear sub-frame is raised into place.
13. Install the draw bolts and washers, then alternately tighten them in 6 mm (1/4 inch) increments until the rear sub-frame is in the installed position.
14. Install the two (2) front retaining bolts in the rear sub-frame. Do not tighten the bolts at this time.
15. One at a time, replace the draw bolts and washers with the two (2) rear retaining bolts in the rear sub-frame.
16. Check the alignment of the scribe marks on the sub-frame to the four (4) mounting bolts.
A. If the marks are in alignment:
^ tighten all four (4) sub-frame bolts to 120 Nm (89 lb-ft).
^ remove the Rear Sub-Frame Alignment Pin Set T94P-2100-AH from the alignment holes of the rear sub-frame.
B. If the marks are not in alignment:
^ remove the Rear Sub-Frame Alignment Pin Set T94P-2100-AH from the alignment holes of the rear sub-frame.
^ shift the sub-frame to align the scribe marks.
^ tighten all four (4) sub-frame bolts to 120 Nm (89 lb-ft).
17. Remove the adjustable jack stand.
18. Engage the exhaust hangers at the following locations:
^ The left inner rocker panel in front of the rear sub-frame.
^ The rear of the vehicle behind the muffler assembly.
19. Lower the vehicle.