Fuel Return System - Modification
Category
4
Applicable Model/s
1983 GLC
Subject
FUEL RETURN SYSTEM MODIFICATION
Bulletin No. 046/83
Issued 6/29/83
Revised
DESCRIPTION
A fuel return kit has been established as a service part to improve driveability for the 1983 GLC.
This modification procedure is based on the followings:
1. Replacement of the carburetor inner parts (needle valve and filter).
2. Routing change of the fuel return hose.
3. Installation of the check valve in the fuel return line.
PARTS INFORMATION
Fuel Return Kit: E564 99 075
Kit componemt parts: (Please refer to page 8, 9 for detailed information).
1. Fuel Hose Connector: 1 pc
2. Filter: 1 pc
3. Needle Valve: 1 pc
4. Needle Valve Body: 1 pc
5. Washer for Needle Valve Body: 1 pc
6. Gasket: 1 pc
7. Cotter Pin: 1 pc
8. "O" Ring for A/F Solenoid: 1 pc
9. Seal Tape: 1 pc
10. Fuel Return Hose (500 mm): 1 pc
11. Fuel Return Hose (350 mm): 1 pc
12. Check Valve: 1 pc
13. Rubber Cap: 1 pc
14. Metal Clip: 4 pc
15. Metal Clip: 1 pc
16. Metal Clip: 1 pc
17. Plastic Clip: 1 pc
18. Plastic Clip: 2 pc
Needle Valve and Filter:
MODIFICATION PROCEDURE
1. Replacement of the needle valve and filter.
a. Disconnect the negative battery cable and remove the air cleaner.
b. Remove the air horn and replace the needle valve, needle valve body and filter with the modified ones which are provided in the kit. Use the new washer for the needle valve body.
Air Horn Removal:
Air Horn Removal Parts:
Note: To remove the air horn, the following hoses and parts must be disconnected.
Float Level:
c. Adjust the float level
Turn the air horn upside-down and allow the float to lower by its own weight.
Clearance (H): 0.433 in. (11.0 mm)
d. Install the air horn with a new gasket and reconnect the accelerating pump lever and choke rod. Use the new cotter pin for the choke rod. Install the screw for the bimetal cover.
Connectors:
2. Routing change of the fuel return hose and installation of the check valve.
a. Replace the fuel hose connector with the modified one.
Note: Wrap seal tape around the thread of the connector about 1-1/4 times.
Metal Clip & Rubber Cap Locations:
b. Remove the fuel return hose between the fuel pump and fuel return pipe, and plug the fuel pump return outlet as shown using the rubber cap and metal clip provided in the kit.
Metal and Plastic Clips Locations:
Hoses and Clip Locations:
c. Connect the small diameter side of the new fuel return hose (longer one) to the fuel hose connector and secure the hose using the metal and plastic clips as shown.
Fuel Return Hose and Pipe:
d. Connect the small diameter side of the new fuel return hose (shorter one) to the fuel return pipe and secure the hose by using the metal clip as shown.
Check Valve and Metal Clips:
e. Install the check valve between the two fuel return hoses and secure it by using the metal clips as shown.
Fuel Main, Air Vent and Return Hoses:
f. Secure the fuel main, air vent and fuel return hoses by using the plastic clips as shown.
g. Connect the hoses which have been disconnected in step 1-b.
3. Final Check
a. Connect the negative battery cable and start the engine.
b. Check for fuel leaks.
c. Check the float level at the sight glass.
d. Turn the engine off and install the air cleaner.
WARRANTY INFORMATION
Customer Comment Code: 1H
Damage Code: 33
Process No.: B3-023
Part No. of Main Cause: E564 99 075
Quantity: 1
Operation No.: XX0008-RX
Labor Hour: 1.0 Hr.
Kit Component Parts:
Kit Component Parts:
KIT COMPONENT PARTS
Fuel Hose Routing Diagram:
FUEL HOSE ROUTING DIAGRAM