Attachment III - Technical Information
OVERVIEWThis program involves the inspection of a fuel tank spot weld and if necessary, the replacement and disposal of the fuel tank.
INSPECTION PROCEDURE
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 of the Workshop Manual.
2. Inspect the rear fuel tank spot weld located on the front section of the RH (passenger) side of the fuel tank for a small cavity or surface depression. See Figure 1.
NOTE:
REFER TO FIGURE 2 FOR SIZE REFERENCE OF SMALL CAVITY OR SURFACE DEPRESSION.
3. If a small cavity or surface depression is present, continue to the Fuel Tank Replacement Procedure.
4. If no small cavity or surface depression is present, no further service action is required.
FUEL TANK REPLACEMENT PROCEDURE
1. Drain the fuel tank. For additional information, refer to Section 310-00 of the Workshop Manual.
2. Remove the fuel tank. For additional information, refer to Section 310-01 of the Workshop Manual. Refer to Figure 3 for reference.
3. Remove the fuel level sensor and set aside.
4. Disconnect the fuel tank harness from the fuel pump module connector. Separate the fuel tank harness from the fuel tank insulation, pushpin, retainer clip and set the harness aside.
5. Disconnect the fuel tank jumper tube and retainer and set the jumper tube aside.
6. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the module and/or float arm.
NOTE:
The FP module will have residual fuel remaining internally. Drain the residual fuel into a suitable container.
NOTE:
Clean the FP module connection, coupling, flange surface and the immediate surrounding area of any dirt or foreign material.
Using special tool number 310-123, remove the FP module lock ring and carefully lift the module out of the fuel tank enough to allow access for disconnecting the internal fuel tube-to-FP module quick connect coupling. For additional information, refer to Section 310-00 of the Workshop Manual.
7. Remove the FP module from the tank and dispose of the original 0-ring seal.
8. Dispose of the fuel tank. Refer to the Fuel Tank Preparation For Disposal Procedure.
9. Position the new fuel tank on a suitable lifting device.
10. Apply clean engine oil to the new FP module 0-ring seal and install it onto the original FP module.
11. NOTE: Make sure the alignment tab on the original FP module and the new fuel tank meet before tightening the original FP module lock ring.
Position the original FP module into the fuel tank and connect the internal fuel-to-FP module quick connect coupling.
12. Using special tool number 310-123, secure the lock ring.
13. Apply clean engine oil to the original fuel level sensor 0-ring seal. Position the fuel level sensor into the fuel tank. Push down firmly on the fuel level sensor and rotate it clockwise until the lock arrow on the sensor aligns with the notch on the fuel tank. Torque should not exceed 15 Nm (133 lb-in).
14. Install the fuel tank jumper tube and retainer.
15. NOTE: Make sure that the fuel tank harness is routed correctly and place under the fuel tank insulation.
Install the fuel tank harness onto the fuel tank and connect the fuel tank wiring harness to the FP module and the fuel level sensor.
16. Install the fuel tank. For additional information, refer to Section 310-01 of the Workshop Manual.
FUEL TANK PREPARATION FOR DISPOSAL PROCEDURE
WARNING:
FAILURE TO PERFORM THIS PROCEDURE AS OUTLINED CAN RESULT IN PERSONAL INJURY.
WARNING:
OVER TIME, THE FUEL NEUTRALIZER WILL ALLOW FUEL TO VAPORIZE AND FUMES WILL COLLECT IN THE TANK. THEREFORE, IT IS IMPORTANT TO PERFORM THE FUEL TANK DISPOSAL PROCEDURE (DRILLING HOLES IN TANK) WITHIN ONE HOUR OF PERFORMING THIS PREPARATION PROCEDURE.
1. Drain as much fuel from the fuel tank as possible. No more than eight (8) to ten (10) ounces of fuel remaining in the fuel tank is acceptable.
2. Pour the entire contents of one (1) four (4) ounce bottle of PM-7A Fuel Neutralizer into an empty one (1) gallon container.
3. Add enough water to fill the one (1) gallon container. Add the water at a rate high enough to thoroughly mix the PM-7A with the water.
4. Pour the entire gallon of the PM-7A/water mixture into the tank.
5. Slosh the PM-7A/water mixture aggressively around the fuel tank for 30 seconds.
6. Let the fuel tank stand for five (5) minutes.
7. Slosh the PM-7A/water mixture aggressively around the fuel tank again for 30 seconds.
8. Dispose of the PM-7A/water mixture following all local and state ordinances.
9. Place a shop exhaust ventilation system hose in the fuel delivery module opening and pull the vapors out of the fuel tank for one (1) minute.
FUEL TANK DISPOSAL PROCEDURE
1. Render the removed fuel tank useless by drilling three (3)25 mm (1 in) holes in the bottom of the tank.
2. Dispose of the fuel tank and contents following all local and state ordinances.