Technical Info. Attachment III

Attachment III-1
VAPOR HOSE Emissions Recall 92E22
INSPECTION/INSTALLATION INSTRUCTIONS


AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines


Inspection Procedure

1. Remove fuel filler cap and attach Fuel Tank Assembly Leak Tester 134-00003 or equivalent.

2. Locate vent tube near the filter on frame rail and separate vent tube from nylon connector. Plug vent tube going to tank.

3. Pump fuel tank assembly leak tester up to 15 inches of water. In 2 minutes, gauge should not drop more than 2 inches of water. If pressure check is OK, do nothing. Inspection is complete. Prepare and install Authorized Modifications Decal shown on Sheet 3.

4. If pressure check results in a failure proceed to reconnect hose.


Reconnect Hose

WARNING:
FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM.

1. Relieve fuel pressure as follows:
- Disconnect inertia switch in luggage compartment.
- Crank engine for 15-20 seconds to relieve pressure.

2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent.

3. Remove exhaust shield screws and remove cross-over support.





4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1).

5. Place safety support under fuel tank and remove four fuel tank support strap bolts, and straps.

6. Lower fuel tank.


7. Remove hoses.





8. Connect the hose from the vapor line to the rollover valve (Figure 2).





9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly.

CAUTION:
While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft (Figure 3).


10. Raise fuel tank.

11. Connect fuel tank hoses to fuel filler pipe.

12. Tighten clamps from hoses to fuel filler pipe.

13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft).

14. Install screws to exhaust shield.

15. Install cross-over support.

16. Prepare and install Authorized Modifications Decal shown below.