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Section I

SECTION I - MODIFIED INSTALLATION PROCEDURE FOR REAR TANK CHECK VALVE - KITS CC AND DD:

ON 1992/93 F-SERIES EQUIPPED WITH A STEEL REAR FUEL TANK, TECHNICIANS MAY FIND IT DIFFICULT TO INSTALL THE CHECK VALVE ON THE REAR TANK. IF YOU ARE NOT CAREFUL WHEN LOWERING THE FUEL TANK, THE PORTS ON THE REAR TANK FUEL DELIVERY MODULE CAN BE BENT. THE FOLLOWING TECHNIQUE SHOULD BE FOLLOWED ON THE REAR TANK (NO CHANGE IN PROCEDURE IS NECESSARY ON THE FRONT TANK). NO CHANGE IN LABOR TIME IS REQUIRED:

1. DRAIN REAR FUEL TANK IF NOT ALREADY NEAR EMPTY. THIS CAN BE DONE BY PUSHING A LARGE HOSE DOWN THE FILLER NECK AND SIPHONING AS MUCH FUEL AS POSSIBLE USING ROTUNDA FUEL STORAGE TANKER 034-00002 OR 034-00014 OR EQUIVALENT.

2. RAISE VEHICLE ON HOIST AND POSITION SUITABLE SAFETY STANDS UNDER VEHICLE.

3. POSITION SPARE TIRE OUT OF THE WAY (IT IS NOT NECESSARY TO COMPLETELY REMOVE THE TIRE AND CARRIER - JUST REMOVE FROM THE HOLD DOWN BOLT AND LET THE TIRE AND CARRIER CAREFULLY SWING DOWN OUT OF THE WAY).

4. LOOSEN HOSE CLAMP AT FUEL FILLER HOSE CONNECTION TO FUEL TANK AND REMOVE HOSE FROM TANK OR, ALTERNATIVELY, REMOVE THE THREE SCREWS ATTACHING THE FILLER NECK TO THE BODY SHEET METAL.

5. POSITION SUITABLE JACK STAND UNDER REAR FUEL TANK.








6. SUPPORT THE TANK AND REMOVE THE BOLTS ATTACHING THE TANK SUPPORTS TO THE FRAME. SLOWLY BEGIN TO LOWER THE TANK WHILE KEEPING THE FRONT OF THE TANK UP AS THE TANK IS LOWERED FROM THE REAR FIRST. SEE FIGURE # 1. MOVE THE TANK A FEW INCHES REARWARD AS THE TANK IS BEING LOWERED - BE SURE THAT THE FUEL LINES AT THE FRONT OF THE TANK ARE MOVING FREELY AND NOT BINDING ON THE CROSSMEMBER. DO NOT LOWER THE TANK MORE THAN 4-5 INCHES. THIS WILL PROVIDE ACCESS TO THE FUEL DELIVERY MODULE AT THE FRONT OF THE TANK. SEE FIGURE # 2. IF THE TANK IS LOWERED MORE THAN 4-5 INCHES, OR IF THE TANK IS LOWERED STRAIGHT DOWN WITHOUT ALSO MOVING IT A FEW INCHES REARWARD, THE FUEL DELIVERY MODULE PORTS COULD BE BENT.

7. DISCONNECT THE FUEL SUPPLY LINE FITTING AT THE FUEL DELIVERY MODULE (REFERENCE APPENDIX I OF INSTRUCTION SHEET 8117 OR 8118 IN KIT CC OR DD FOR REMOVAL PROCEDURE). SEE FIGURE # 2 ABOVE. NOTE: FOR PURPOSES OF CLARITY, THE FUEL LINE SAFETY CLIPS ARE NOT SHOWN - THEY ARE REQUIRED.





8. WITH THE FUEL SUPPLY LINE STILL DISCONNECTED, CAREFULLY MOVE THE FUEL TANK BACK INTO POSITION BY LIFTING THE FRONT OF THE TANK FIRST. BE CAREFUL NOT TO KINK THE FUEL LINES AT THE FRONT OF THE TANK. SEE FIGURE # 3. POSITION FUEL TANK SUPPORTS AND INSTALL ATTACHING BOLTS AND NUTS. TIGHTEN TO 37-50 N-m (27-37 FT.LB.). FOR ADDITIONAL INFORMATION, SEE TSB 91-23-10.

9. RECONNECT THE FUEL FILLER HOSE TO THE FUEL TANK AND TIGHTEN CLAMP TO 3-4 N-m (25-35 IN.LB.) OR, IF THE FILLER NECK WAS REMOVED AT THE BODY SHEET METAL, REATTACH WITH THE THREE SCREWS.

10. INSTALL CHECK VALVE CONNECTOR TO THE FUEL SUPPLY LINE FIRST (NOT TO THE FUEL DELIVERY MODULE). NOTE: MAKE SURE TO INSTALL THE SAFETY CLIP CONNECTING THE FUEL LINE AND THE CHECK VALVE AND TO POSITION IT SO THE LONG LEGS OF THE CLIP WILL BE HORIZONTAL TO THE GROUND WHEN ATTACHED TO THE FUEL DELIVERY MODULE IN STEP # 12.

11. PRE-POSITION THE SECOND SAFETY CLIP ON THE OTHER END OF THE CHECK VALVE CONNECTOR (IF NOT ALREADY PRE-POSITIONED - SEE NOTE IN STEP # 10).





12. CONNECT THE FUEL SUPPLY LINE AND CHECK VALVE CONNECTOR ASSEMBLY (WITH SAFETY CLIP PRE-POSITIONED) TO THE FUEL DELIVERY MODULE BY INSERTING THROUGH THE SPACE BETWEEN THE FRAME CROSSMEMBER AND THE PICKUP BOX BED SUPPORT. SEE FIGURE # 4 AND # 5 BELOW. DO NOT ATTACH UNTIL A SAFETY CLIP IS PRE-POSITIONED ON THE OPEN END OF THE CHECK VALVE CONNECTOR AND THE OTHER SAFETY CLIP IS ATTACHED BETWEEN THE CHECK VALVE AND THE FUEL SUPPLY LINE. (REFERENCE APPENDIX I OF INSTRUCTION SHEET 8117 OR 8118 IN KIT CC OR DD FOR INSTALLATION PROCEDURE). AFTER THE FUEL LINE AND CHECK VALVE CONNECTOR ARE ATTACHED TO THE FUEL DELIVERY MODULE, USE A LARGE FLAT BLADE SCREWDRIVER TO FULLY SEAT THE SAFETY CLIP ONTO THE SUPPLY LINE OF THE FUEL DELIVERY MODULE AND THE CHECK VALVE. MAKE SURE TO POSITION THE SAFETY CLIP SO THE LEGS OF THE CLIP WILL BE HORIZONTAL TO THE GROUND WHEN ATTACHED TO THE FUEL DELIVERY MODULE. BOTH SAFETY CLIPS MUST BE INSTALLED.

13. REMOVE JACK AND REPOSITION SPARE TIRE.

14. CONTINUE WITH INSTALLATION OF FRONT FUEL TANK CHECK VALVE AND FUEL PRESSURE REGULATOR PER THE INSTRUCTION SHEET PACKED WITH KITS CC AND DD.
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