Fuel Tank Breather - Modified
Group: 20Number: 82-01
Date: April 12, 1982
Subject: Fuel Tank Breather System
Key Points: Modification Effective from June 1981 on
A modified fuel-tank breather was introduced in production starting in June 1981.
^ 924 (VIN 92 BN 45 1969)
^ 924 Turbo (VIN 93 BN 15 1492)
Parts Kit Description
Note:
The new parts can be installed on earlier cars (1980/1981 with tank flap in body).
Previous-type filler necks (for model 1980 and 1981), Part Number 477 201129 E, is no longer available as service part.
On vehicles earlier than 1980 (without tank flap in body), it is impossible to install the new breather system.
New breather, installing
- disconnect battery
- remove luggage compartment carpet and sound insulation material
- remove right rear side panel trim
- partially remove side panel carpet at filler neck
- loosen white plastic cover on filler neck at fasteners (arrows) and remove
- loosen clips for breather hose on filler neck and pull hose off
- remove existing cable binders on filler neck
- loosen hose clips on connecting hose
- pull hose off tank and filler neck
- take tank cap off and pull filler neck out inward. Cover adaptor pipe on tank to prevent dirt from entering tank
- remove short hose (arrow) from roll-over valve to tank breather line and discard
- install new hose, Part No. 477 201 159H in place of discarded hose
- remove pressure valve for carbon canister (arrow) and discard. Do not hook up hoses yet
- connect hoses for new breather system as shown.
^ molded hose (Item 2 in illustration) with pressure valve (Item 3 in illustration) and hose elbow (Item 4 in illustration) must be fitted on the curved upward leading pipe on the filler neck.
^ the molded hose (Item 2 in illustration) must be routed in a curve from top to bottom behind the filler neck, free of kinks
^ the roll-over valve (Item 10 in illustration) must remain vertical in the bracket
^ spray connecting hose (Item 13 in illustration) lightly with silicone lubricant and push it, complete with clips, on to tank connecting pipe
^ insert filler neck upwards and install in connecting hose
Note:
Ensure that rubber hoses are installed properly. Do not tighten hose clips yet
Determine position of new filler neck as follows:
- put tank cap on and close flap. Flap must not touch cap
- tighten both hose clips, and secure filler neck with plastic straps
- tighten all hose clips, and secure hoses that run along filler neck to the neck with plastic straps
Note:
Fit hose clips carefully; do not twist when tightening. Route hoses free of kinks
- reinstall white plastic cover
- check operation of system as follows:
- take tank cap off
- blow compressed air into hose that goes to carbon canister
^ fuel-tank breather system is working properly when a slight draft of air is felt at the filler neck opening
- reconnect both hoses to carbon canister
- reconnect battery
- reinstall sound insulation and carpet
Labor Operation: 2007210
Time Allowance: 75 T.U.