Fuel Tank - Frequent Nozzle Shutoff When Fueling
Article No.98-15-3
08/03/98
FUEL - FREQUENT SHUTOFF OF FUEL HANDLE
WHEN FILLING FUEL TANK
FORD:
1998 CONTOUR
This TSB article is being republished in its entirety to include 1999 Cougar, remove reference to vehicle build dates, and include the latest level parts.
LINCOLN-MERCURY:
1998 MYSTIQUE
1999 COUGAR
ISSUE
Frequent shutoff of the fuel handle when filling the fuel tank may occur on some vehicles. This may be caused by the flapper valve in the fuel filler pipe sticking and not opening fully to allow fuel fill. The flapper valve sticking may be due to it swelling and distorting when exposed to ethanol fuels.
ACTION
Replace the flapper valve with a revised flapper valve. Refer to the Service Procedure for details.
SERVICE PROCEDURE
CAUTION
DO NOT ATTEMPT TO REPLACE THE FLAPPER VALVE WITHOUT COMPLETE FUEL FILLER PIPE AND TANK REMOVAL FROM THE VEHICLE. ATTEMPTING TO REPLACE THE FLAPPER VALVE WITHOUT COMPLETELY REMOVING THE FILLER PIPE AND TANK MAY RESULT IN DISLODGING THE INNER FUEL TANK FILLER SEAL.
1. Remove the fuel tank and filler pipe assembly from the vehicle by referring to the 1998 Contour/Mystique or 1999 Cougar Workshop Manual, Section 310-01.
2. Remove the fuel filler pipe from the fuel tank.
3. Firmly secure the fuel filler pipe retaining bracket in a bench vise. Do not clamp the pipe in the vise or the pipe will be distorted.
NOTE
IF FUEL FILLER PIPE IS DISTORTED, FLAPPER VALVE BINDING MAY RESULT. REPLACE A BENT OR DISTORTED FUEL FILLER PIPE.
4. Open fuel filler pipe flapper valve and grasp with pliers. Remove the valve by twisting in a circular motion until hinge pins shear. Using caution to avoid filler pipe distortion, use a 3/8" center punch to carefully punch out the flapper valve housing retaining tabs (Figure 1).
5. Remove the flapper valve plastic housing from the fuel filler pipe. Be sure to remove all remaining plastic debris from the filler pipe before installing the revised flapper valve.
6. Position the revised Flapper Valve (F8RZ-9U085-AC) on the end of the filler pipe. Align the flapper valve retaining tabs with the windows in the filler pipe (Figure 2).
7. Using a small rubber mallet, carefully tap the revised flapper valve into position in the filler pipe. Make sure both flapper valve alignment tabs are centered and fully seated in the filler pipe windows. If the alignment tabs are not positioned correctly in the window, replace the flapper valve.
8. Confirm free operation of the flapper valve. The valve must fall open and closed under its own weight when the filler pipe is inverted. If the flapper valve does not open and close under its own weight, check for filler pipe distortion and improper flapper valve retaining tab alignment. A distorted filler pipe must be replaced.
NOTE
LIGHTLY LUBRICATE THE SEAL AND THE FUEL FILLER NECK WITH PETROLEUM JELLY TO HELP EASE FILLER PIPE REINSTALLATION. MAKE SURE INNER FUEL TANK FILLER SEAL IS IN POSITION AND THAT IT DOES NOT BECOME DISLODGED DURING FUEL TANK FILLER PIPE INSTALLATION.
9. Reinstall the fuel filler pipe into the fuel tank.
10. Reinstall the fuel tank and filler pipe assembly into the vehicle by referring to the Workshop Manual, Section 310-01.
11. Perform the Evaporative Emission System Leak Test as follows:
CAUTION
THE EVAPORATIVE EMISSION SYSTEM MUST NOT BE PRESSURIZED TO MORE THAN 3.48 kPa (14 INCHES H2O) OR DAMAGE TO THE EVAPORATIVE EMISSION SYSTEM MAY OCCUR.
a. Connect the Evaporative Emission System Leak Tester (Rotunda 134-00056).
NOTE
THE IGNITION SWITCH MUST BE IN THE KEY ON AND ENGINE OFF (KOEO) POSITION.
NOTE
BE SURE THE FUEL FILLER CAP IS PROPERLY TORQUED TO THE FIRST "CLICK."
b. Using the New Generation Star (NGS) Tester, apply 12 volts to the canister vent solenoid.
c. Pressurize the evaporative emission system to 3.48 kPa (14 inches H2O).
d. Monitor the system for 2 minutes. The system fails leak test if pressure tails below 2.0 kPa (8 inches H2O).
e. Repair any leaks as required.
f Repeat the Leak Test - Evaporative Emission System - until the system remains above 2.0 kPa (8 inches H2O) after the 2 minute test period.
PART NUMBER PART NAME
F8RZ-9U085-AC Fuel Pipe Flapper valve
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-20-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
981503A Replace Flapper Valve As 2.7 Hrs.
Outlined (Includes Time To
Replace Fuel Filler Pipe If
Required)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9U085 41
OASIS CODES: 404000