Attachment III - Technical Information

FUEL LINE INSPECTION AND MODIFICATION

AFFECTED VEHICLES
1999 Contour, Cougar and Mystique

INSPECTION

1. Cycle ignition key 5 times to pressurize fuel system.

2. Raise and support vehicle.





3. Locate fuel supply line "plastic to steel joint." See Figure 1.

4. Clean plastic to steel joint of any foreign material. If joint is covered with undercoating, call Recall Hotline at 1-800-325-5621 for further directions.

5. Visually inspect joint for signs of fuel seepage. Also pay attention to any fuel odors that may be present in the area.





6. Using a cotton swab, wipe around entire joint. See Figure 2.

^ If cotton swab is dry and does not smell like gasoline, no service action is required. Fill out and attach "Authorized Modifications Label" as outlined at the end of these instructions. Return vehicle to customer or saleable stock.

^ If cotton swab is moist or smells like gasoline, the fuel supply line must be modified as outlined in the "Service Procedure."

SERVICE PROCEDURE

1. Raise and support vehicle, if necessary.





2. Locate two (2) fuel line flares where fuel hose slides over fuel line. See Figure 3. The flares show up as bumps in the fuel hose. Mark both bumps with a white marker.





3. Install supplied sleeve over the two marks. Index the slit in the sleeve to approximately the 3:30 position. Refer to Figure 4.

4. Transfer marks placed on fuel hose to the sleeve. See Figure 4.

NOTE:
Proper placement and torque must be used in the following step.





5. Install supplied clamps over marks placed previously, in direction and orientation shown in Figure 5. Tighten the clamps to 4.5 Nm (40 lb-in). Make sure there is clearance between the clamps and all other lines and underbody components.





6. Install extra routing clip as shown in Figure 6. Make sure base of the clip is facing the floor pan of the vehicle (open side facing down).

7. Cycle ignition key five (5) times to pressurize fuel system. Check the fuel line for seepage.

8. Lower vehicle.

9. Fill out and attach "Authorized Modifications Label" as outlined at the end of these instructions.

AUTHORIZED MODIFICATIONS LABEL





^ Obtain, prepare and attach the Authorized Modifications Label. Write in the modification description, your P and A Code, the change authorization and date of repair as shown below.

^ Apply label to clear area of the upper radiator support.

^ Provide California and Massachusetts owners with "Emissions Recall -- Proof of Corrections" Certificates.