Attachment III - Technical Information
OVERVIEWThis program involves inspecting the fuel tank build date code to determine if the fuel tank must be replaced.
INSPECTION
1. Raise the vehicle on a hoist.
2. NOTE: The fuel tank build date code is stamped into the rear face of the left side (driver side) of the tank.
NOTE:
The build date code is formatted as MONTH DAY YEAR -x. For example, the stamping may read 022205-x which denotes the tank was built on February 22, 2005. See Figures 1 and 2.
Note:
The first two (2) digits of the date code may be hidden beneath the left fuel tank support strap. These hidden numbers represent the month the tank was built. Due to the extremely limited number of vehicles that are being recalled for inspection (approximately 60), not being able to clearly see the first two (2) numbers of the date code is not important. The fuel tanks that are being inspected were built within a two-day span in February 2005, of which approximately half of those may require replacement.
Check the fuel tank build date code.
^ If the fuel tank was built on either February 22nd or February 23rd, 2005 (date codes 022205 and 022305), the fuel tank must be replaced. Refer to the appropriate fuel tank replacement procedure in this Attachment III.
^ If the fuel tank was built before or after the subject dates, no further service is required.
FUEL TANK REPLACEMENT
Be sure to follow all Workshop Repair Manual Notes, Cautions and Warnings related to fuel system service.
Refer to the 2005 Thunderbird or LS Workshop Repair Manual for Fuel Tank service procedures and review the notes below before proceeding. The procedures that need to be followed include:
^ Fuel System Pressure Release (Section 310-00)
^ Rear Seat Cushion Removal and Installation, LS only (Section 501-10)
^ Fuel Tank Draining (Section 310-00)
^ Fuel Tank Removal and Installation (Section 310-01)
^ Fuel Pump Module and the Fuel Transfer Pump Removal and Installation (to be done once the tank has been removed from the vehicle) (Section 310-01)
For Thunderbird Only:
NOTE:
It is necessary to remove the sill plates in order to remove the rear trim panels as part of the fuel tank draining procedure.
NOTE:
It may be necessary to loosen the left side bolts on the underbody cross brace to allow repositioning of the fuel tube shield. After the new tank is installed and the fuel tube shield is back in place, tighten the cross brace bolts to 63 Nm (46 lb-ft).
For Both Thunderbird and LS:
NOTE
When lowering the fuel tank during the draining procedure, it may be necessary to physically pull the tank down away from the underbody even after loosening the tank support straps. The NVH pads located at the top of the fuel tank may have adhered to the underbody and may cause the tank to stick in place.
NOTE:
The fuel and vapor tube assemblies must be transferred to the replacement fuel tank.
^ If necessary, when transferring the vapor tubes to the valves on the fuel tank, use new screw type clamps obtained locally. Proper clamp orientation is necessary to avoid clamp contact with the floor pan. Be sure to orient the clamps on the large diameter hose so the screw is perpendicular to the tank (pointing straight down). Orient the clamps on the smaller hoses so the screws are parallel to the tank. See Figure 3. Tighten the clamps until snug and then an additional two (2) revolutions. Be sure to tighten clamps properly or evaporative emissions leaks may result, which could lead to setting a DTC and turning on the MIL.
^ When reinstalling the fuel pump module and fuel transfer pump lock rings, tighten both to 80 N-m (59 lb-ft). Not tighting these to specifications could result in evaporative emissions leaks which could lead to setting a DTC and turning on the MIL.
NOTE:
Install two (2) white NVH foam pads (part number XW4Z-9A068-AA) over the evaporative emission tubes to insulate them from contacting the floor pan. Remove the paper and secure the new foam pads, using the original fuel tank as a guide. See Figure 4.
NOTE:
Install tow (2) black NVH foam pads (part number 2W4Z-9A068-AA) to each area on the top of the fuel tank. Remove the paper backing and secure the new foam pads, using the original fuel tank as a guide.