Attachment III - Technical Information
AFFECTED VEHICLES:1996 TAURUS AND SABLE
WARNING
DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN FUELING THE VEHICLE OR WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT.HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
WARNING
AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS.
WARNING
ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION.FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY SUCH AS BLINDNESS.
WARNING
IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION.MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD.
WARNING
DO NOT OPERATE ENGINE WHILE REFUELING.
INSPECTION
1. Raise and support vehicle.
2. Inspect right rear corner of fuel tank for plastic plug. See Figures 1 and 2.
3. If plastic plug is present, the fuel tank must be replaced. Proceed to "Fuel Tank Replacement." If plastic plug is not present, no service action is required. Return vehicle to customer.
FUEL TANK REPLACEMENT
1. Lower vehicle.
2. Install memory saver.
3. Relieve fuel system pressure as follows:
^ Unscrew and remove fuel pressure relief valve cap.
^ Connect Multiport Fuel Injection Fuel Pressure Gauge T80L-9974-B to the fuel pressure relief valve.
^ Open manual valve on gauge to relieve fuel system pressure.
4. Disconnect battery negative cable.
5. Drain fuel tank.
6. Raise and support vehicle.
7. Disconnect fuel filler and vent tubes from fuel tank hoses. See Figure 3.
8. Disconnect vapor line at rear of fuel tank. Refer to Figure 4.
9. Disconnect EVAP canister vacuum line. See Figure 4.
10. Disconnect fuel supply and return lines at the fuel filter. Refer to Figure 5.
11. Disconnect the fuel pump electrical connector. See Figure 5.
12. Support fuel tank with adjustable jack.
13. Remove fuel tank straps retaining bolts. Position straps aside.
14. Lower fuel tank.
15. Place fuel tank on clean, flat work surface.
16. Clean fuel tank to prevent foreign material from damaging components.
17. Remove fuel filler and vent hoses from the fuel tank. Refer to Figure 6.
18. Remove fuel control valve assembly from fuel tank. Refer to Figure 6.
19. Disconnect and remove fuel pressure transducer. Refer to Figure 6.
20. Remove fuel pump lock-ring, then remove fuel pump. See Figure 6.
21. Remove fuel pump seal.
22. Discard original fuel tank.
23. Place new fuel tank on clean, flat work surface.
24. Lubricate and install fuel pump seal.
25. Install fuel pump. Tighten lock ring until it contacts stops.
26. Install and connect fuel pressure transducer.
27. Install fuel control valve assembly to fuel tank.
28. Install fuel filler and vent hoses to fuel tank.
29. Position fuel tank on adjustable jack.
30. Install fuel tank in vehicle. Tighten fuel tank straps to 30-40 Nm (22-30 lb ft.).
31. Remove adjustable jack.
32. Connect fuel pump electrical connector.
33. Connect fuel supply and return line at the fuel filter.
34. Connect EVAP canister vacuum line.
35. Connect vapor line at rear of fuel tank.
36. Connect fuel filler and vent tube to fuel tank hoses.
37. Lower vehicle.
38. Fill fuel tank.
39. Connect battery negative cable, then remove memory saver.
40. Start and run engine.
41. Raise vehicle.
42. Inspect fuel system for leaks.
43. Lower vehicle.