Attachment III - Technical Instructions
Vapor Valve Assembly ReplacementAffected Vehicles:
1995 Model U.S and Canadian Taurus Flex Fuel Vehicles Manufactured at the Chicago Assembly Plant November 9 through 14, 1994.
WARNING
DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
Removal
1. Connect Rotunda Fuel Pressure Test Kit 134-R0035 or Universal Fuel Pressure Test Kit 134-R0094 to fuel pressure relief valve located near the cold start injector on the hand side of the intake manifold.
2. Open the manual valve on the gauge to relieve fuel pressure.
3. Disconnect gauge from pressure relief valve.
NOTE:
The Flexible Fuel Vehicle Fuel Tank cannot be drained through the Fuel Tank Filler Pipe. A special screen is installed in the Fuel Tank Filler Pipe to prevent siphoning of fuel through the Fuel Tank Filler Pipe. The fuel tank on this vehicle is equipped with a drain tube connected to the Fuel Pump Module on the RH side of the vehicle, which has a quick disconnect for this purpose. It is not necessary to lower the fuel tank to drain the system. See Figure 1.
4. Install Rotunda Memory Saver 021-00062 then disconnect battery negative cable.
NOTE:
Memory Saver will retain memory in radio settings, clock, engine strategy, etc.
5. Raise vehicle on hoist.
6. Remove foam cover and protective rubber cover from the fuel tank drain tube.
7. Connect drain tube quick disconnect fitting to Rotunda Fuel Storage Tanker and Adapter Hose 034-000020. Drain Fuel from tank.
8. Once all fuel is drained from tank, disconnect adapter hose from fuel tank drain tube. Reinstall protective rubber cover and foam cover.
9. Disconnect fuel filler pipe and vent hose at fuel tank connections.
10. Disconnect fuel filler pip sensing tube and carbon canister hose push connect fitting from vapor valve assembly.
11. Disconnect exhaust system rear hangers and allow exhaust to hang on rear suspension arm.
12. Position jack under fuel tank.
13. Remove fuel tank strap retaining bolts, then remove pins and straps. See Figure 2.
14. Lower tank (approximately 150-200 mm {6-8 Inches}) for access to Vapor Valve assembly.
15. Disengage vapor control from its mounting bracket. Remove vapor orifice and rollover valve assemblies from their rubber grommets and remove assembly from the vehicle.
CAUTION
Be sure both grommets are in place in fuel tank openings.
Installation
1. Install new valve assembly (F3DZ-9C047-CFFV) ensuring vapor orifice and rollover valve assemblies are fully seated in their grommets and vapor control valve is securely mounted in its bracket. See Figure 3.
2. Position fuel tank in place and install support straps with pins. Install retaining bolts and tighten to 29-41N-m (22-30 ft-lb).
3. Remove jack from under vehicle.
4. Connect fuel filler pipe sensing tube and carbon canister hose to vapor valve connections.
5. Connect fuel filler pipe and vent hose to fuel tank.
6. Position exhaust system and secure rubber mounts.
7. Lower hoist.
8. Replace fuel drained from tank.
9. Connect battery negative cable and remove Memory Saver.
10. Start engine and check all connections for leaks.
Authorized Modifications Labels And California "Emissions Recall-Proof Of Corrections" Certificates
^ Obtain, prepare and attach an Authorized Modifications Label (available at no-charge {package of 25 with overlay} as part number FPS-8262 on DOES II). Write on the label "Vapor Valve Assembly Replaced", authority, "Emissions Recall 94E55", your P&A Code and date of repair as shown below.
^ Provide California owners with "Emissions Recall-Proof of Correction" Certificates.
Authorized Modifications Decal