Fuel Tank Y Fitting - New Replacement Method
Section2
Group
23
No.
0026
Year
99
Month
10
850/S70/V70
1996-1998
Vehicles Involved: Non ORVR vehicles (Onboard Refueling Vapor Recovery)
Y-fitting on fuel tank, new method
Background:
This service bulletin describes how to replace the Y-fitting on the fuel tank. If for any reason the Y-fitting needs to be replaced, the fitting is now available as a separate spare part.
Model Factory Emission code.
850(4 drs)/S70 1, 2, 3 Emission code 3,4
850(5 drs)/V70 2, 3 (8th position in VIN)
Materials
Description Quantity Part No.
Fitting 1 9480050-5
Special Tool
adepter J-41031-A
fixture J-41470-850
bleeder hose 999 5480
Y-fitting on fuel tank, new method
Y-fitting on fuel tank
Draining the fuel system and fuel tank
1
Removing covers
Remove:
- throttle pulley cover,
- the cap from the valve on the fuel rail.
2
Draining the fuel system
Connect open end of adapter J-41031-A to the fuel drainage unit.
Connect the adapter to the valve on the fuel rail
3
Raise the vehicle.
Remove the valve protector next to the fuel filter. Connect bleeder hose 999 5480 to valve in front of fuel filter. It takes approximately 2 minutes to drain the fuel system.
Start evacuating fuel.
4
Reinstalling components
Reinstall components in reverse order.
Caution!
Remember to reinstall the valve caps.
5
Draining the fuel tank
Use hose of draining unit to empty fuel tank.
Note!
Insert the hose at least 1 m. (40") into fuel tank.
Removing fuel tank and replacing the Y-fitting with hoses
6
Preparations
5-door cars
Remove all floor hatches and pull the carpet out of the way.
Remove the cover over the fuel pump (FP) unit.
4-door cars
Fold down right rear seat.
Remove the cargo compartment carpet.
Pull back the corner of inner wheel housing panel at the shock absorber mounting.
Remove the cover over the fuel pump (FP) unit.
7
Removing connectors
Separate all connectors on the bracket.
Remove the wrapped rubber grommet around the wiring. Ensure that all wires routed through the fuel pump (FP) unit hole are unimpeded and can exit when fuel tank is lowered.
8
Disconnecting hoses
Carefully remove the fuel delivery line and return line quick-release connectors by pressing up the locking with special tool 999 5666 and then pulling straight up.
9
Removing filler neck
Remove filler cap.
Remove lock ring that expands rubber seal.
Release rubber seal from body.
10
Lowering the fuel tank
Place a transmission jack with fixture J-41470-85O under the fuel tank. Strap the fuel tank to the fixture (arrows).
Undo the tank retaining straps and lower the tank slightly.
11
Removing the retainer
Remove hose retainer from the bracket by pulling it to the right side of the car.
12
Removing the Y-fitting with hoses
Caution!
Ensure that no fuel line or wires are kinked and/or damaged while lowering the tank.
Carefully continue to lower the tank just enough to gain access to the hoses to top of the tank.
Remove fuel tank pressure sensor (A).
Remove the hose assembly (B).
13
Installing the Y- fitting with hoses
Install:
- the new hose assembly,
- hose (B) with spring clamp,
- the tank pressure sensor,
- hoses (C) with clamps as illustrated.
Installing fuel tank
14
Raising the fuel tank
Carefully raise the tank enough so that front hose retainer can be installed on the bracket.
Position the wiring correctly so that it will enter through the access hole for the fuel pump (FP) unit. Ensure that no wires are pinched or chafed when the fuel tank is raised.
15
Securing the fuel tank
Caution!
Ensure that no fuel line or wires are kinked and/or pinched while raising tank to body.
Carefully continue raising the fuel tank and tighten it to the body.
Torque screws to 25 Nm (20 ft.lbs)
16
Installing rubber boot, lock clip
Lubricate rubber boot sealing surfaces (2) with petroleum jelly.
Reinstall the rubber boot. Ensure correct position in relation to body panels. (see illustration)
Ensure that inner rubber (1) seal is correctly seated and that the drain pipe (3) is positioned as per illustration.
Install lock clip (4).
17
Connectors and finishing work
Assemble connectors to fuel pump (FP), level sensor, fuel tank pressure sensor and ABS sensors.
Install:
- wrap rubber grommet around the wiring,
- access cover fuel pump, panels, and carpet.
18
Checking diagnostic trouble codes (DTC's)
Erase diagnostic trouble codes (DTC's). Start engine to ensure operation.
Check so that no diagnostic trouble codes (DTC's) have been stored.
WARRANTY STATEMENT: Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.
Operation No. Labor description Time allowance
23963-2 Replacing the Y-fitting, fuel tank 1.8 hr