Attachment III - Technical Information

AFFECTED VEHICLES:
CERTAIN 1998 CONTOUR, MYSTIQUE AND CERTAIN 1999 COUGAR VEHICLES

OVERVIEW

This procedure provides the detail to replace the fuel tank filler pipe flapper valve assembly (located at the end of the filler pipe) and the fuel tank filler neck grommet.

REMOVAL





1. Relieve fuel system pressure. Remove the fuel pump relay from the power distribution box under the hood. Run the engine until it runs out of fuel. Then crank the engine a few more seconds to make sure any residual fuel pressure is relieved. Then turn the key to OFF and reinstall the relay. See Figure 1.

2. Install memory saver and disconnect the battery negative cable.

NOTE:
The end of the 3/8 in. hose must be trimmed to a point to allow for insertion into the fuel tank.

3. Using Rotunda Fuel Tanker 034-00014 or equivalent and a suitable length of 3/8-inch hose, remove the fuel from the fuel tank.

4. Raise and support the vehicle on a hoist.





5. Disconnect the fuel line from the fuel filter outlet fitting. See Figure 2.





6. Position a tall jack stand at the forward end of the muffler and pipe assembly. Remove the muffler inlet pipe flange nuts. Then disengage the hangers and remove the muffler and pipe assembly from the vehicle. See Figure 3





7. Remove the exhaust heat shield from the fuel tank area. See Figure 4.





8. Disconnect the rear sway bar links from the lower suspension arms. Then remove the sway bar brackets and the sway bar from the vehicle. See Figure 5.

9. Remove the two (2) filler neck bracket retainer bolts.

10. Using Rotunda Powertrain Lift or equivalent, support the fuel tank.





11. Remove the fuel tank strap bolts and position the straps out of the way. See Figure 6.

12. Partially lower the fuel tank.

NOTE:
There are minor differences between non-returnless and returnless fuel systems. A returnless fuel system may have fewer items to disconnect in the fuel tank area than those listed below.

13. Disconnect the following from the fuel tank. See Figure 7.

a. pressure sensor electrical connector.

b. [1][2]fuel pump module electrical connector.

c. fuel line.

d. vapor tube (2 connections).

e. fuel vent hoses.

f. fuel filler pipe.





14. Remove the fuel tank and set it on a suitable work surface.





15. Using suitable pliers, remove the flapper valve from the housing by twisting it until the hinge pins shear. See Figure 8. Then remove the valve housing, using a 318-inch center punch to carefully punch out the housing retaining tabs through the retaining tab windows. Be sure to remove any remaining plastic debris from the filler pipe.





16. Remove the fuel filler neck grommet from the fuel tank. See Figure 9.