REMOVAL & INSTALLATION
The fuel system, depending on model year of the vehicle, may be equipped with push type connectors or spring lock couplings. When removing the fuel lines on these vehicles, it will be necessary to use Fuel Line Coupling Disconnect Tool D87L-9280-A or-B, or equivalent.
Quick-Connect (push) type fittings must be disconnected using proper procedures or the fitting may be damaged. Two types of retainers are used on the push connect fittings. Line sizes of3/8in. and5/16in. use a hairpin clip retainer.1/4in. line connectors use a Duck bill clip retainer.Push Connect (Steel) Fittings
See Figures 1, 2, 3 and 4
- Relieve the fuel system pressure.
- Open the safety clip and fit tools T90T-9550-B ( 5 / 16 in. or T90T-9550-C ( 3 / 8 in. to the coupling so that the tool enters the female fitting.
- Push the tool into the female fitting so that it releases the retaining fingers from the male tube end.
- Pull the fittings apart and remove the tool.
- Inspect the lines and fittings for damage.
- Push the two ends of the fittings together until an audible click is heard.
- Pull on the fitting to make sure that it is properly connected.
- Lock the assembly with a safety clip, start the van and check for leaks
See Figures 5 through 9
If the fuel system is equipped with spring lock couplings, remove the retaining clip from the spring lock coupling by hand only. Do not use any sharp tool or screwdriver, as it may damage the spring lock coupling.
- Relieve the fuel system pressure.
- Twist the fitting to free it from any adhesion at the O-ring seals.
Inspect the condition of the O-ring seals and replace them with the correct parts, if necessary.
- Fit Spring Lock Coupling Tool T81P-19623-G1/G2 or equivalent to the coupling.
- Close the tool and push it into the open side of the cage to expand the garter spring and release the female fitting.
- After the garter spring is expanded, pull the fitting and tube apart.
- Remove the tool from the disconnected coupling.
- Lubricate the O-rings with refrigerant oil and insert the white indicator ring into the cage of the male fitting.
- Push the couplings together with a slight twisting motion until the white indicator ring pops free.
See Figure 10
- Clean all dirt and/or grease from the fittings. Spread the two clip legs about an 1 / 8 in. each to disengage from the fitting and pull the clip outward from the fitting. Use finger pressure only, do not use any tools.
- Grasp the fittings and hose assembly and pull away from the steel line. Twist the fitting and hose assembly slightly while pulling, if necessary, when a sticking condition exists.
- Inspect the hairpin clip for damage, replace the clip if necessary. Reinstall the clip in position on the fitting.
- Inspect the fitting and inside of the connector to ensure freedom of dirt or obstruction. Install the fitting into the connector and push together. A click will be heard when the hairpin snaps into its proper position. Pull on the line to insure full engagement.
See Figure 11
- A special tool is available for Ford for removing the retaining clip (Ford Tool No. T82L-9500-AH). If the tool is not available, see Step 2. Align the slot on the push connector disconnect tool with either tab on the retaining clip. Pull the line from the connector.
- If the special clip tool is not available, use a pair of narrow 6 in. (152mm) locking pliers with a jaw width of 0.2 in. (5mm) or less. Align the jaws of the pliers with the openings of the fitting case and compress the part of the retaining clip that engages the case. Compressing the retaining clip will release the fitting, which may then be pulled from the connector. Both sides of the clip must be compressed at the same time to disengage.
- Inspect the retaining clip, fitting end and connector. Replace the clip if any damage is apparent.
- Push the line into the steel connector until a click is heard, indicating that the clip is in place. Pull on the line to check engagement.