Service Procedure, Label & Claim Information
SERVICE PROCEDURE1. Handling flammable liquids.
CAUTION: Before attempting service of any type on the fuel tank, always:
a. Place "no smoking" signs near work area.
b. Be sure to have C02 Dry Chemical (Class B) fire extinguisher handy.
c. Wear safety glasses.
d. Siphon or pump fuel into an explosion proof container.
e. Avoid fuel spillage - gasoline fumes are heavier than air and will collect at floor level.
f. Wear gloves to protect against sharp edges.
2. Fuel pressure relief procedure:
CAUTION: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. To do this:
a. Disconnect fuel tank harness connector.
b. Crank engine, engine will start and run until fuel supply remaining in fuel lines is consumed. Engage starter for 3.0 seconds to assure relief of any remaining pressure.
c. Turn ignition off. Unless this procedure is followed before servicing fuel lines or connections, fuel spray could occur.
3. Drain fuel tank using hand operated pump.
CAUTION: Never drain or store gasoline in open container due to the possibility of fire or explosion.
4. Disconnect the negative battery cable.
5. Disconnect the fuel feed and return lines at the frame rail. Cap the fuel lines to reduce spillage.
6. Loosen the hose clamp and disconnect the vapor hose.
7. Loosen clamps and disconnect the filler neck and vent hose. Remove two exhaust hanger bolts at rear and lower exhaust enough to gain access to fuel tank. Support exhaust with jack stand or cable, etc. Loosen exhaust heat shield and let hang free on pipe. Remove parking brake cable bracket at left fuel tank strap.
8. Support fuel tank and loosen the tank strap bolts and lower the fuel tank.
9. Loosen the fuel sender cam lock ring using special tool J 24187-A.
10. Remove the fuel sender assembly and transfer the lock ring and the two pipe insulators onto the new sender.
11. Install new O-Ring gasket on tank opening.
12. Install new fuel sender and pump assembly (25094448) with a rollover valve into the tank.
^ Take caution not to damage or deform pipe or break solder connection at sender cover.
^ Take caution in installing the sender to not damage the float assembly.
13. Rotate cam lock ring to the stops using the special tool J 24187-A.
14. Verify that the fuel sender pipes are insulated from top of the fuel tank.
15. Verify fuel tank and underbody noise isolation rubber strips remain in proper position.
16. Install fuel tank to vehicle. Tighten strap bolts to 34 N-m (23 ft.lbs.).
17. Reconnect the filler neck and torque clamps to 2.5 N-m (20 in.lbs.).
^ Assure hose is fully seated and .is not kinked or twisted.
^ Position clamps for servicing.
18. Reinstall parking brake cable bracket, exhaust shield, and exhaust pipe.
19. Reconnect the fuel tank harness connector.
20. Reconnect fuel lines and torque nuts to 27 N-m (22 ft.lbs.). Tighten clamp to 1.6 N-m (12 in.lbs.)
21. Verify that fuel line nuts and/or hose clamp do not contact the underbody.
22. Reinstall fuel in tank.
DO NOT RUN FUEL PUMP WHEN TANK IS DRY.
23. Connect the negative battery cable.
24. Start the engine and let it idle.
25. Raise the vehicle and check for fuel leaks at the tank and fuel line connections.
26. Lower the vehicle and verify fuel gage function.
27. Install campaign identification label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the campaign number, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7901-709).
CLAIM INFORMATION
A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.
DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:
Other*
Failure Labor Labor Labor Net**
Operation Code Operation Hours Hours Amount
Replace Fuel Sender
and Pump Assembly 96 V4900 1.1 .1 $47.34
* Dealers will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.
** The $47.34 identified in the "Net Amount" column represents 30% of the
current price of furnished parts. This allowance should be listed as a net items figure in the sublet column of the warranty claim.
FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.
Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.
RECORDING COMPLETION
Repairs submitted for vehicles not involved in the campaign will not be paid.
Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS."