Attachment III - Technical Information
FUEL SYSTEM MODIFICATIONAffected Vehicles:
1996 TAURUS FLEX FUEL VEHICLES (FFV) BUILT AT THE CHICAGO ASSEMBLY PLANT DURING 1996 MODEL YEAR PRODUCTION
SERVICE KIT PART NUMBER: F7DZ-9B357-AA
KIT CONTENTS
WARNING:
DO NOT SMOKE, CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN FUELING THE VEHICLE OR WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
WARNING:
DO NOT SWALLOW METHANOL OR ETHANOL FUEL. LIKE GASOLINE, THESE FUELS ARE HIGHLY TOXIC AND IF SWALLOWED CAN CAUSE DEATH OR PERMANENT INJURY. SWALLOWING METHANOL CAN ALSO CAUSE BLINDNESS. CALL A PHYSICIAN IMMEDIATELY TO TREAT ANYONE WHO HAS SWALLOWED METHANOL OR ETHANOL FUEL. VOMITING SHOULD BE INDUCED BY OR UNDER THE DIRECTION OF A PHYSICIAN OR POISON CONTROL CENTER. BE AWARE THAT THE ONSET OF POTENTIAL ILL HEALTH EFFECTS MAY BE DELAYED.
WARNING:
AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY SUCH AS BLINDNESS.
WARNING:
AVOID GETTING METHANOL FUEL, ETHANOL FUEL OR GASOLINE LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES: REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY SUCH AS BLINDNESS.
WARNING:
IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD.
WARNING:
IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH METHANOL FUEL OR ETHANOL FUEL OR BREATHING ITS VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOL. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH METHANOL FUEL OR ETHANOL FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET METHANOL FUEL OR ETHANOL FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION.
WARNING:
DO NOT MODIFY THE FUEL SYSTEM CONFIGURATION OR COMPONENTS, OR REPLACE COMPONENTS WITH PARTS NOT ESPECIALLY DESIGNED FOR USE WITH METHANOL FUEL OR ETHANOL FUEL. FORD MOTOR COMPANY HAS SPECIALLY-DESIGNED THE MATERIALS,COMPONENTS AND SYSTEM CONFIGURATION FOR METHANOL-FUELED VEHICLES AND EACH PARTICULAR SYSTEM IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. FORD ETHANOL VEHICLES REQUIRE THE SAME COMPONENTS AS METHANOL VEHICLES, BUT ARE PRECISELY CALIBRATED FOR EFFICIENT OPERATION ONLY ON GASOLINE/ETHANOL BLENDS. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, PERSONAL INJURY OR COULD CAUSE ENGINE DAMAGE.
WARNING:
METHANOL AND ETHANOL VEHICLES ARE DESIGNED TO USE SPECIFIC FUEL BLENDS. DO NOT USE FUEL BLENDS NOT DESIGNATED FOR SPECIFIC VEHICLES. SEE FUEL FILLER DOOR FOR PROPER FUEL USAGE. INTRODUCTION OF IMPROPER FUEL MAY CAUSE ENGINE DAMAGE.
CAUTION:
Use only fuels which meet the specifications issued by the American Automobile Manufacturers Association (AAMA) and of the type specified for the calibration number printed on the calibration decal. Use of other fuels may cause powertrain damage as well as loss of vehicle performance. It will also invalidate the Ford Warranty and any extended service agreement.
Component Removal
This procedure will replace the fuel vapor control valve tube assembly and the fuel pump internal electrical connector seal.
1. Install memory saver, then disconnect battery negative cable.
2. Relieve fuel system pressure as follows:
^ Unscrew and remove cap from the pressure relief valve on the fuel supply injection manifold.
^ Connect Rotunda Fuel (methanol or ethanol) Pressure Test Kit 134-R0035, or equivalent, to the pressure relief valve.
^ Open the manual valve of the pressure kit to relieve fuel system pressure.
3. Drain fuel tank as follows:
^ Disconnect the fuel return line from the fuel supply injection manifold, using Spring Lock Coupling Disconnect Tool D87L-9280-A or B. See Figure 1. There are two (2) fuel line tubes. Disconnect the fuel line at the outlet connector.
^ Connect adaptor hose to the fuel return line.
^ Connect adaptor to the appropriate Rotunda fuel storage tanker. Use storage tanker Rotunda 164-R3201, or equivalent, on vehicles that have 100 percent gasoline in the fuel tank. Use storage tanker Rotunda 1 64-R3210, or equivalent, on vehicles that have a blend of methanol or ethanol and gasoline.
^ Pump all fuel from the fuel tank.
4. Remove the fuel filler cap.
5. Remove fuel filler pipe-to-wheel well retaining screws.
6 Remove retaining screw from splash shield in right wheel well. Position splash shield aside.
7. Raise and support vehicle.
8. Remove the fuel tank filler pipe reinforcing bracket retaining screw.
9. Disconnect fuel tank filler pipe hoses from fuel tank.
10. Disconnect fuel supply, return and emission lines. See Figure 2.
11. Disconnect the fuel pump electrical connector.
12. Support fuel tank with suitable jack.
13. Remove fuel tank strap retaining bolts. Position straps aside.
14. Lower the fuel tank.
15. Place fuel tank on bench.
16. Remove hose from fuel filler pipe vent tube. See Figure 3.
17. Remove the fuel control valve bracket retaining screw, then remove the two vapor vent valves from their grommets. See Figure 4. Remove assembly from the fuel tank.
18. Detach fuel pump module wiring harness from fuel tank lip.
19. Disconnect electrical connector from the fuel tank pressure/vacuum transducer.
20. Remove both fuel supply and return hoses from the fuel pump.
21. Remove fuel pump locking flange and gasket, then lift fuel pump module cover. Refer to Figure 5.
22. Disconnect fuel pump module internal electrical connector. Refer to Figure 5.
23. Remove electrical connector seal. See Figure 5.
Component Installation
1. Install cap and clamp on fuel filler pipe vent tube. See Figure 6.
2. Install new internal electrical connector seal. See Figure 7.
3. Install new looking flange gasket.
4. Position fuel pump module cover on fuel tank. Install locking flange.
5. Install both fuel supply and return hoses to the fuel pump.
6. Connect electrical connector to the fuel tank pressure/vacuum transducer.
7. Attach fuel pump module wiring harness to fuel tank lip.
8. Install new fuel vapor control valve tube assembly on the fuel tank. See Figure 8.
9. Install fuel vapor control valve bracket retaining screw. Tighten retaining screw to 8-10 Nm (71-89 lb-in).
10. Insert vapor vent valves in their grommets.
11. Place fuel tank assembly on jack, then raise fuel tank to installed position.
12. Connect fuel pump electrical connector.
13. Position fuel tank straps, then install retaining bolts. Tighten retaining bolts to 30-40 Nm (22-30 lb-ft).
14. Connect fuel supply, return and vapor lines.
15. Connect fuel tank filler pipe hoses to the fuel tank.
16. Install filler pipe reinforcing bracket retaining screw. Tighten screw to 4-6 Nm (35-53 lb-in).
17. Lower vehicle.
18. Position right wheel well splash shield, then install retaining screw. Tighten screw securely.
19. Install fuel filler pipe-to-wheel well retaining screws. Tighten screws to 2.7-3.7 Nm (24-33 lb-in).
20. Install fuel filler cap.
21. Fill fuel tank.
22. Connect battery negative cable, then remove memory saver.
AUTHORIZED MODIFICATIONS LABELS AND CALIFORNIA "EMISSIONS RECALL- PROOF OF CORRECTIONS" CERTIFICATES
^ Prepare and attach the preprinted Authorized Modifications Label provided in the kit of parts. Write your P & A Code and date of repair as shown.
^ Provide California owners with "Emissions Recall-Proof of Correction" Certificates.