Attachment III - Technical Information

OVERVIEW

This program involves replacing both fuel tank straps on the affected vehicles. Draining the fuel tank will not be required since only one strap will be replaced at a time and a tall jackstand will be used to support the tank. The plastic pushpin retainers that are being cut off were used as a production assembly aid only. Replacing them is not required. Also, a commercially available 13 mm torque adapter is required to tighten the strap rear bolts on the front wheel drive sedan applications due to the limited clearance behind the fuel tank.

SERVICE PROCEDURE

NOTE:
Replace the RIGHT SIDE (passenger side) fuel tank strap first.

1. NOTE: It is not necessary to drain any fuel from the tank before disconnecting the filler tube from the fuel tank even if it is full. Fuel will not spill if the vehicle is raised level on a hoist.

On Five Hundred and Montego FWD models only, disconnect the fuel filler tube from the fuel tank.

2. Position a tall jackstand under the right side (passenger side) of the fuel tank to support its weight. Do not place the stand under the heat shield.





3. Using side cutters, cut off the two (2) plastic pushpin retainers protruding through the heat shield and tank strap. See Figure 1.

4. Remove the fuel tank strap bolts and remove the strap from the vehicle. On Five Hundred and Montego FWD vehicles, discard the REAR bolt only. See Figure 1.

5. Remove and discard the heads of the plastic pushpin retainers from above the heat shield.

6. CAUTION: Do not bend the straps during installation.

CAUTION:
The service kits for the Five Hundred and Montego FWD vehicles comes with a new; shorter rear bolt. The original rear bolts must be discarded.

Position a new strap in place and install the rear retainer bolt first, then the front bolt. Tighten the bolts hand tight at this time.

7. Reposition the jack to the other side of the tank, then repeat Steps 2 though 5 to replace the left side strap.

8. Remove the jack when strap replacement is completed.

9. CAUTION: Proper fuel tank strap bolt torque is critical to the performance of the straps.

Tighten the bolts to 35 Nm (26 lb-ft).

NOTE:
Access to the fuel tank strap rear bolts varies from model to model. The following information is provided as a guide when tightening the rear strap bolts.





Remember - Items such as deep sockets and torque wrenches vary greatly in size not only from manufacturer to manufacturer, but each manufacturer may offer different size wrenches as well. When using a crowfoot wrench or a torque adapter, calculate the proper torque wrench setting based on tool dimensions. See Figure 2.

^ Freestyle FWD - tighten the bolts using a torque wrench and standard shallow socket.

^ Freestyle AWD - tighten the bolts using a crowfoot wrench on an extension positioned in the pocket of the lower control arm-to-inboard pivot bushing.

^ Five Hundred / Montego FWD - tighten the bolts using a torque wrench and a commercially available torque adapter positioned above the rear subframe.

^ Five Hundred / Montego AWD - tighten the bolts using a torque wrench and a deep socket positioned above the rear subframe.

10. Connect the fuel filler tube to the fuel tank. Tighten the clamp to 3 Nm (27 lb-in). (Five Hundred and Montego FWD models only)