Technical Instructions - Attachment III
ATTACHMENT III
SAFETY RECALL 91S21
Fuel Line-to-Intermediate Steering Shaft Clearance
TECHNICAL INSTRUCTIONS
The fuel supply and return lines may have been bent and/or misrouted at assembly. Those vehicles with fuel lines correctly routed but with inadequate clearance between the fuel lines and intermediate steering shaft must have the lines repositioned. Those vehicles that have damaged or misrouted fuel lines must have the lines replaced.
CLEARANCE INSPECTION
The fuel lines are located on the left side of the car.
^ If the lines come up from the dash panel on the outboard side (fender side) of steering shaft, the fuel line routing is correct. Inspect the lines for proper clearance and/or wear.
^ If the lines come up from the dash on inboard side (engine side) of the steering shaft, the fuel lilie routing is incorrect. Replace that section of fuel line regardless of wear or contact. Refer to the replacement procedures described below.
^ The clearance between the fuel lines and steering shaft should be approximately 3/4" at the closest point. Also, for cars without ABS, check the clearance between the brake line coming from the master cylinder and the fuel lines. This clearance should be approximately 7/8".
CLEARANCE ADJUSTMENTS
If the clearances listed above are incorrect, reposition the fuel lines as follows:
1. Disconnect the battery.
2. Relieve fuel system pressure and disconnect the fuel supply and return lines at the fuel rail. Refer to Section 24-50 of the shop manual for the procedures.
3. Starting at the dash panel, follow the fuel lines up and bend them to improve clearance where necessary. The adjustments should be made at existing bend points, if possible.
ATTACHMENT III
NOTE: Steel tubes have to be slightly over-bent due to spring-back after bending.
4. Reconnect the fuel lines to the fuel rail.
5. Reconnect the battery.
6. Inspect the fuel lines for leaks and proper clearances.
FUEL LINE REPLACEMENT
If the fuel lines are improperly routed or show witness marks of contact or wear from the steering shaft or brake tube, replace the damaged section of fuel line as follows:
1. Disconnect the battery.
2. Relieve fuel system pressure and disconnect the fuel supply and return lines at the fuel rail. Refer to Section 24-50 of the shop manual for the procedures.
3. From under the hood, remove the plastic clip and cut the tie strap on the protective cover.
4. Raise the car on a hoist.
FIGURE 1:
5. Cut the second tie strap on the protective cover.
6. Remove the five (5) clip bolts securing the fuel/brake lines to the frame. See Figure 1.
7. Unsnap the fuel lines from the second and forward most plastic clips.
8. Cut the tie strap located between the second and third plastic clips.
9. Compare the service replacement fuel line assembly with the existing fuel line. Mark the fuel lines for cutting; allowing for the length of the flareless union fitting.
10. Cut the existing fuel lines (supply and return lines) with a small tube cutter. Cut the lines so that the repair assembly will follow original fuel line routing in the torque box area. Be sure to allow for the length of the flareless union fitting.
11. Remove the cut fuel lines by pulling down and rearward.
ATTACHMENT III
12. Square the ends of the cut tubing with a file. Remove burrs. Blow out any particles with compressed air.
13. Position the service replacement fuel line assembly in the car by passing it in from underneath. Be sure that the fuel lines are routed properly on the outboard side (fender side) of the steering shaft.
14. The vehicle should be lowered so that the fuel lines can be initially adjusted in the engine compartment. The fuel lines should be placed so they will attach to the fuel rail and have proper clearance to the steering shaft and other components.
15. Raise the car.
16. Assemble the flareless union fitting by sliding the nut over the tubing with the threaded (open) end out.
17. Slide the ferrule on the tubing with the cutting edge out, the large head end should be inside of the nut. Lubricate the ferrule and the threads on the fasteners with oil.
18. Bottom the tube in the fitting, and tighten the nut until the ferrule just grips the tube. When the tube can no longer be turned by hand the ferrule has started to grip.
19. After the ferrule grips the tube, tighten the nut one full turn.
20. Repeat the procedure for each end of the fittings.
21. Snap the service replacement fuel line assembly into the forward most plastic clip and start the bolts in both the steel clip and the forward most plastic clips. See Figure 1.
FIGURE 2:
22. Position the protective rubber cover (slit rubber hose) over the fuel supply line fitting so that it covers that fitting completely. Tie strap the cover in two places to hold it in place. See Figure 2.
23. Snap the fuel lines into the second plastic clip.
24. Install the bolts in the second, third and fourth plastic clips. Then, tighten all five (5) clip bolts to secure the fuel lines. Torque the bolts to 7 lb.ft. (10 N-m).
25. Reinspect the fuel lines for proper routing from below.
26. Lower the vehicle.
27. Place fuel lines in position for connection to fuel rail.
ATTACHMENT III
28. Inspect fuel lines for proper clearance. Adjust if required.
29. Reconnect the fuel lines to the fuel rail.
30. Install the fuel line retaining clips.
31. Reconnect the battery.
32. Inspect the fuel lines for leaks and proper clearance.