Attachment III - Technical Information
OVERVIEW
This program involves replacing the fuel delivery module (FDM) with a new, redesigned module. The new module is top-mounted in the tank and requires the removal of the retaining ring that attaches the original FDM to the floor of the tank. Cut-off tool 310-133 has been designed to cut the tabs of the retaining ring without damaging the fuel tank vapor barrier (inside surface of the tank).
FUEL SYSTEM PRESSURE RELEASE AND FUEL TANK DRAINING
WARNING:
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE VAPORS ARE ALWAYS PRESENT AND MAY IGNITE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
WARNING:
THE FUEL SYSTEM REMAINS PRESSURIZED FOR A LONG TIME AFTER THE IGNITION IS SWITCHED OFF. THE FUEL PRESSURE MUST BE RELIEVED BEFORE ATTEMPTING ANY REPAIRS. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
1. Record the radio stations and disconnect the battery ground cable.
2. Remove the fuel filler cap.
3. CAUTION: The fuel tanker used to store the removed fuel must be equipped with a filtering system. Rotunda Fuel Tankers, such as model 034-00014 or 034-00004, are equipped with the necessary filtering systems.
NOTE:
Use an appropriate length hose attached to the end of the fuel tanker drain hose to drain the vehicle fuel tank. To enable the adapter hose to enter the tank, a 40-mm long taper may need to be cut in the end of the hose.
Drain the fuel tank using a tanker and hose as specified.
4. WARNING: MAKE SURE THE TAP ON THE FUEL PRESSURE GAUGE 310-012 (T80L-9974-B) IS TURNED FULLY CLOCKWISE BEFORE CONNECTING IT TO THE SCHRADER VALVE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
While the fuel tank is draining, relieve the fuel system pressure as follows:
a) Remove the air cleaner outlet tube.
b) Remove the cap from the Schrader valve on the fuel manifold.
c) Connect the Fuel Pressure Gauge 310-012 or equivalent to the Schrader valve.
d) With the end of the gauge hose in a suitable container, turn the tap fully counterclockwise to relieve the fuel pressure.
e) Remove the gauge from the Schrader valve and reinstall the valve cap and air cleaner outlet tube.
FUEL TANK AND FUEL DELIVERY MODULE REMOVAL
1. Raise and support the vehicle on a hoist.
2. CAUTION: Support the exhaust system as described to prevent any damage from occurring.
Support the exhaust system using either a tall jack stand or a bungee strap at the tailpipe, then disconnect the four (4) exhaust system rubber hangers.
3. Remove the two (2) stamped nuts and carefully position the heat shield aside to allow access to the left-side fuel tank support strap bolt.
4. Place a suitable drain pan under the fuel filter.
5. Disconnect the fuel filter outlet tube by first removing the retaining clip, then pulling the connector off the filter. Discard the retaining clip.
6. Remove the stabilizer bar clamps and allow the bar to hang by the links. This will provide added access for fuel tank removal and installation.
7. Support the fuel tank using an appropriate lift table or equivalent.
8. Remove the filler pipe lower bolt from the subframe.
9. Remove the fuel tank support strap bolts and position the straps down.
10. CAUTION: When lowering the fuel tank, make sure that excessive strain is not placed on the hoses or electrical harness and connectors.
Partially lower the fuel tank.
11. WARNING: EYE AND EAR PROTECTION IS REQUIRED WHEN USING COMPRESSED AIR TO CLEAN THE FUEL TANK DEBRIS.
Using compressed air, clean the debris from around and inside the filler pipe area to help eliminate any contaminants from entering the fuel tank.
12. CAUTION: When lowering the fuel tank, make sure that excessive strain is not placed on the hoses or electrical harness and connectors.
Disconnect the fuel tank filler pipe from the tank as follows:
a) Push the locking collar down.
b) Turn the locking collar approximately 45 degrees either right or left.
c) Using a small pry bar, work the locking collar up out of the gray filler pipe connector, at the same time lowering the fuel tank to allow the filler pipe to exit the tank. Keep the filler neck opening as parallel as possible with the filler pipe so the pipe does not become wedged in the tank and hinder tank removal.
13. With the tank partially lowered, disconnect the fuel delivery module electrical connector (at the FDM) and the two (2) fuel vent hoses and the vapor tube (near the rear of the tank). Discard the clamps. Disconnect the pressure sensor electrical connector (applicable to early 1999 models only).
14. Lower the tank and place on a suitable workbench.
15. Disconnect the fuel outlet tube from the FDM.
16. Using suitable tools, remove the fuel delivery module locking ring.
Discard the locking ring.
17. Unlock the FDM from the retaining ring in the tank by rotating it counterclockwise, then lift the pump from the tank.
18. Remove and discard the FDM O-ring seal.
19. Using Cut-Off Tool 310-133, remove the FDM retaining ring from the floor of the fuel tank. Refer to the following instructions for proper tool usage. Be sure to follow all notes and cautions regarding tool usage or damage to the fuel tank may occur.
FDM RETAINING RING REMOVAL
TOOL LOCATING AND CUTTING OFF BLACK RETAINING TABS
^ Guide the tool into the tank.
^ Center tool over one (1) of the black retaining tabs.
^ Use the locating features of the tool to aid in positioning. (See cut-off tool illustration.)
^ Allow the tool to rest on the retaining ring floor.
^ Hold the tool vertically to assure a proper cut. (Make sure the tool is centered over the black retaining tab.)
^ Squeeze the tool handles together and cut the black retaining tab.
^ Repeat until all four (4) tabs are cut.
^ Remove and discard FDM retaining ring.
IMPORTANT NOTE
When all four (4) tabs are fully cut, the ring will then be detached and easily removed. If the ring cannot be easily removed, the tool was not positioned properly.
Check the tool position and recut.
Do not rock, twist, pull or pry the tool under any circumstances!!!
FUEL TANK FILLER NECK GROMMET, FLAPPER VALVE AND LOCKING COLLAR REPLACEMENT
1. CAUTION: Use caution when removing the filler neck grommet. Do not damage the filler neck flange when removing the grommet.
Using a suitable tool, carefully remove the filler neck grommet from the fuel tank filler neck flange.
Discard the grommet.
2. Clean any fuel or dirt present in the grommet seating area.
3. CAUTION: Do not lubricate the outside of the grommet or the filler neck flange. It may cause the grommet to be dislodged during fuel tank filler pipe installation.
Install a new grommet, making sure it is fully seated.
4. Using suitable pliers, remove the flapper valve from the filler pipe by twisting it until the hinge pins shear. Then remove the valve housing using a 3/8-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.
5. Position the new flapper valve on the end of the filler pipe and align the retaining tabs with the windows in the filler pipe.
6. Using a light-weight hammer, and with a block of wood placed between the flapper valve and the hammer, gently tap the flapper valve into place. Be sure both flapper valve retaining tabs are seated firmly in the filler pipe windows once the valve is in place.
7. Confirm proper flapper valve operation. The valve must open and close under its own weight. If it does not, check for proper flapper valve retaining tab alignment or fuel filler pipe distortion.
8. Remove the white locking collar from the filler pipe and discard.
9. Install the new locking collar.
FUEL DELIVERY MODULE INSTALLATION
1. Make sure the O-ring groove is clean and the area around the FDM opening is free of loose dirt and debris, then install a new O-ring seal onto the fuel tank.
2. NOTE: Make sure the legs supporting the FDM upper plate are fully extended prior to FDM installation.
Position the new FDM in the tank.
3. Using suitable tools, install and tighten the new fuel delivery module locking ring.
4. NOTE: The new FDM is constructed with the outlet tube and electrical connector reversed as compared to the original FDM.
Connect the FDM fuel outlet tube.
5. Position the protective foam pad aside and install the supplied convolute over the FDM outlet tube as shown in the illustration with the slit facing up. Use vinyl tape to secure the convolute in place by taping both ends to the outlet tube.
FUEL TANK INSTALLATION
1. CAUTION: Do not use silicone to lubricate any fuel system component. Damage to certain components may occur.
NOTE:
Lightly lubricating the grommet and the fuel filler pipe with petroleum jelly will help ease filler pipe reinstallation and prevent dislodging the grommet during tank installation.
Using petroleum jelly, lightly lubricate the filler pipe and the INSIDE of the grommet.
2. Position tank on suitable lift table and partially raise the tank into position and guide the filler pipe only part way into the tank. DO NOT attempt to fully seat the filler pipe at this time.
3. Position the new clamps on the fuel vent hoses. Connect the vent hoses and the vapor tube, then tighten the vent hose clamps.
4. Connect the FDM electrical connector and the pressure sensor electrical connector, if applicable.
5. Continue to raise the tank into position, making sure the filler pipe is properly entering the grommet. Then engage the white filler pipe locking collar into the filler neck flange once the tank is fully in position.
6. Position and secure the fuel tank support straps. Tighten the retaining bolts to 24 Nm (18 lb-ft).
7. Install the filler pipe lower bolt.
8. Install the new retaining clip onto the fuel filter outlet tube connector, then connect the tube to the fuel filter outlet. Tug on the line to make sure of proper connection.
9. Position the stabilizer bar and install the clamps and bolts. Tighten the bolts to 23 Nm (17 lb-ft.).
10. Position the heat shield and install the stamped nuts.
11. Reconnect the exhaust system rubber hangers.
12. Lower the hoist.
13. Return the drained and filtered fuel back into the vehicle fuel tank.
14. Connect the battery negative cable and reset the radio stations.
15. Perform an Evaporative Emissions System Leak Test as follows:
CAUTION:
The evaporative emission system must not be pressurized to more than 3.48 kPa (14 inches H20) or damage to the evaporative emission system may occur.
a) Connect the Evaporative Emission System Leak Tester 310-F007 (134-00056 or equivalent) to the evaporative test port.
b) NOTE: The ignition switch must be in the Key ON/Engine OFF position. Using WDS, NGS or equivalent, apply 12 volts to the canister vent solenoid.
c) Pressurize the evaporative emissions system to 3.48 kPa (14 inches H20).
d) Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (8 inches H20), the system has failed the leak test.
e) Repair any leaks as necessary. (NOTE: Any repairs not related directly to the FDM replacement are not covered by this program.)
f) Repeat the Evaporative Emissions System Leak Test until the system remains above 2.0 kPa (8 inches H20) after the last test period.
16. Perform a post-repair road test to determine that the driveability concern has been corrected.