Attachment III - Technical Information
OVERVIEWThis program involves replacing the fuel tank shell.
You will be directed to the Workshop Repair Manual Section 310-00 for the following fuel tank service:
^ Fuel System Pressure Release
^ Fuel Tank Removal and Installation
^ Fuel Pump Module Removal and Installation
This Attachment III will provide instructions for the following:
^ Heat shield transfer
^ Fuel and vapor tube transfer
^ Detailed views of the in-tank fuel line connection at the fuel pump module
^ Fuel tank disposal
^ Fuel tube quick connect fitting disconnect and reconnect
FUEL TANK REMOVAL
WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, WHICH CAN CAUSE PERSONAL INJURY OR A FIRE HAZARD.
CAUTION:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
CAUTION:
When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.
1. Refer to the online version of the 2007 F-150 Workshop Repair Manual, Section 310-00, for the latest service procedures. Be sure to review all removal notes, cautions and warnings. Release fuel pressure, drain the tank as necessary and remove the tank from the vehicle.
2. Retain the fuel tank straps and bolts for reuse.
COMPONENT TRANSFER
REMOVAL
1. Remove the fuel pump module following the Workshop Repair Manual. Refer to the Fuel Tube Quick Connect Fitting instructions in this Attachment III. Be aware of a fourth fitting inside the fuel tank that connects to the underside of the fuel pump module upper plate. See Figure 1.
2. Remove the heat shields by pulling the retaining rivet center pins outward, then prying the rivets from the shields. See Figure 2.
3. CAUTION: Disengage the fuel and vapor tubes tram the clips by hand. Use extreme care if prying them out of the clips to avoid damaging the tubes.
Carefully remove the fuel and vapor tubes from the 4 retaining clips. See Figure 3.
INSTALLATION
1. Position the fuel and vapor tubes in place and snap them into the 4 retainer clips.
2. Position the heat shields and secure with the removed rivets. Note that the plastic shield goes OVER the metallic shield.
3. Install the fuel pump module O-ring, then position the fuel pump module and connect the internal fuel tube. See Figure 1. After the tube is connected to the port, squeeze the locking tab to fully engage the lock mechanism. See Figure 5. Then, tug on the tube to make sure the fitting is fully seated.
4. Refer to the Workshop Repair Manual as necessary for the final fuel pump module installation instructions.
FUEL TANK INSTALLATION
1. Refer to the Workshop Repair Manual Section 310-00 for fuel tank installation instructions. Be sure to review all installation notes, cautions and warnings.
2. Proceed to Fuel Tank Preparation For Disposal in this Attachment III.
FUEL TANK PREPARATION FOR DISPOSAL
WARNING:
FAILURE TO PERFORM THIS PROCEDURE AS OUTLINED CAN RESULT IN PERSONAL INJURY.
WARNING:
OVER TIME, THE FUEL NEUTRALIZER WILL ALLOW FUEL TO VAPORIZE AND FUMES WILL COLLECT IN THE TANK. THEREFORE, IT IS IMPORTANT TO PERFORM THE FUEL TANK DISPOSAL PROCEDURE (DRILLING HOLES IN TANK) WITHIN ONE HOUR OF PERFORMING THIS PREPARATION PROCEDURE.
1. Drain as much fuel from the fuel tank as possible. No more than 238.6-295.7 ml (8-10 oz) of fuel remaining in the fuel tank is acceptable.
2. Pour the entire contents of one 118.3 ml (4 oz) bottle of PM-7A Fuel Neutralizer into an empty one gallon container.
3. Add enough water to fill the one gallon container. Add the water at a rate high enough to thoroughly mix the PM-7A with the water.
4. Pour the entire gallon of the PM-7A/water mixture into the tank.
5. Slosh the PM-7AIwater mixture aggressively around the fuel tank for 30 seconds.
6. Let the fuel tank stand for 5 minutes.
7. Slosh the PM-7A/water mixture aggressively around the fuel tank again for 30 seconds.
8. Dispose of the PM-7Nwater mixture following all local and state ordinances.
9. Place a shop exhaust ventilation system hose in the fuel delivery module opening and pull the vapors out of the fuel tank for one minute.
FUEL TANK DISPOSAL
1. Render the removed fuel tank useless by drilling several 25 mm (1 in) holes in the bottom of the tank. Also, using a small pair of pliers, reach inside the tank and remove the spring from the fuel fill valve, then drill a hole in the base of the filler neck.
2. Dispose of the fuel tank and contents following all local and state ordinances.
FUEL TUBE QUICK CONNECT FITTING
There are 2 different types of fuel tube quick connect fittings. Review these warnings, cautions and instructions to safely and properly disconnect and reconnect the fittings. If the connector fitting retainer clip is found to be broken or damaged, refer to the instructions provided with the Fuel Line kit.
WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, WHICH CAN CAUSE PERSONAL INJURY OR A FIRE HAZARD.
CAUTION:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
CAUTION:
When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.
TYPE A FITTING
1. To disconnect: See Figure 4.
A) Press the tab corners to release the locking tab.
B) Pull the locking tab to the release position.
C) Disconnect the quick connect fitting.
^ Push the fitting toward the tube to release pressure.
^ Press the tab corners to release the fitting.
^ Disconnect the quick connect fitting.
2. To reconnect: See Figure 5.
CAUTION:
Make sure the quick connect fitting clicks into place when installing the tube. To make sure that the quick connect fitting is fully seated, pull on the tube.
NOTE:
Apply clean engine oil to the end of the tube before connecting the fitting.
A) Connect the tube into the quick connect fitting.
B) Press the locking tab down into the locked position. Verity proper connection by gently pulling on the tube.
TYPE B FITTING
1. To disconnect: See Figure 6.
A) Push the connector toward the tube to release pressure, then press the quick release fitting button and pull the fuel tube to disconnect.
2. To reconnect: See Figure 7.
CAUTION:
Make sure the quick connect fitting clicks into place when installing the tube. To make sure that the quick connect fitting is fully seated, pull on the tube.
NOTE:
Apply clean engine oil to the end of the tube before connecting the fitting.
A) Connect the quick release fitting. Verify proper connection by gently pulling on the tube.