ts10-043 pdc new verso - fuel tank concern - check and repair procedure - attachment 2

8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2

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Attachment 2

0FB01 PDC New Verso Fuel Tank Concern Check and Repair Procedure

Content Page

1. Operation Flow Chart 2

2. Fuel Tank Barcode Check Procedure 3

3. Fuel Tank Check Procedure 4-7

1. OPERATION FLOW CHART

!

This Check and Repair Procedure contents detailed information/descriptions only for two steps:

> Check Fuel Tank Barcode (Section-2)

> Check Inside Fuel Tank (Section-3)

For any other operations (removal of parts, installation of parts, tools needed, confirmations and quality

check etc...) Please refer Tech Doc documentation.

Before proceeding step "Check Inside Fuel Tank and Confirm Fuel Tank is OK or NG", take necessary

safety measures. And When working on fuel tank pay highest attention to safety.

It is highly recommended to print this document in high quality color. If this is not possible, use computer

screen to see OK NG pictures of fuel tank during check inside fuel tank step.



Check VIN

Check barcode of fuel tank

and confirm fuel tank affected or not

[Please refer to Section-2 ]

No action required.

Release the vehicle

Actual vehicle VIN

is within the given list

and PDC not done

Fuel Tank is Affected ?

YES

No action required.

Release the vehicle

NO

YES

Order gasket (1/vehiche)

77169-0D030

Gasket, Fuel suction tube set

Check Inside Fuel Tank

and Confirm Fuel Tank is OK or NG(Please refer to Section-3)

Order new fuel tank (1/vehicle)

77001-0F030 Tank assy, Fuel (Gasoline)

77001-0F040 Tank assy, Fuel (Diesel)

Tank is OK or NG?

By using new gasket re-install pump.

Re-install all other parts.

Make a quality check.Release the vehicle

OK

NG

Please note that re-use of

old gasket strictlyforbidden.

Remove fuel tank from the vehicle,

Drain fuel inside and Scrap NG tank

NO

Install new fuel tank with new gasket.

Re-install all other parts.

Put enough fuel (same amount drained from

old tank)

Make a quality check.

Release the vehicle

!

!Please note that re-use of

old gasket strictly forbidden

!This operation requires removal of fuel pump.

To do so, please follow repair manual instructions in Tech Doc.

Please follow repair manual instructions in Tech Doc

!Please follow repair manual

instructions in Tech Doc

If there is doubt about OK

NG condition, judge NG and

replace the tank.

!

Note1: Affected does not necessarily

mean tank is NG, it can be OK or NG.

Affected means tank is suspicious

checking inside tank is needed as

described in the following steps.

Note2: Vehicles leave production plant in

agerage 5 liters of fuel. If for some

reason fuel is added in logistics and/or atdealers, fuel must be drained before next

step.

Note3: When scrapping NG fuel tanks, please follow local

waste disposal procedures.



2. FUEL TANK BARCODE CHECK PROCEDURE

Last 11 (eleven) digits of fuel tank barcode is less than 04072058274 , AFFECTED

Last 11 (eleven) digits of fuel tank barcode is bigger than 04072058274 , NOT AFFECTED

Barcode No: 170611004052158535

Last 11 Digits: 04052158535

Less than 04072058274, so tank

AFFECTED checking inside tank

is needed

Example-1:

Barcode No: 170411004152303455

Last 11 Digits: 04152303455

Bigger than 04072058274, so tank

is OK, NOT AFFECTED

Example-2:

FUEL TANK BARCODE LOCATION

Fuel tank barcode is at the bottom side of fuel tank and can be easi ly seen from under the vehicle

even vehicle is not lifted up.

RR LH TIRE SIDE OF VEHICLE

Look from to under of vehicle Fuel Tank Barcode

HOW TO CONFIRM FUEL TANK IS AFFECTED OR NOT

Note: Affected does not necessarily mean tank is NG, it can be OK or NG. Affected means tank is

suspicious checking inside tank is needed as described in this procedure.



Sketch for inspection posture

Inspect kiss-off area inside the fuel tank at fuel tank breather tube connector side with a torch.

3. FUEL TANK CHECK PROCEDURE

Check Inside Fuel Tank and Confirm Fuel Tank is OK or NG.

3.1. Where to check: Check Kiss-off area

Check point (kiss-off) is inside fuel tank towards

backward of the vehicle.

FRONTREAR

KISS-OFF area is here

Use small torch or other light source

to illuminate inside the tank



3.2. Actual vision with correct inspection posture

KISS-OFF area is here.

This is where upper and

lower parts of fuel thank

comes together.



3.3. How to Judge OK or NG

There are two different type of potential problems, 1- Separation (Void), 2- V shape.

For both cases, below sketches/pictures shows OK and NG (Separation and V shape) conditions.

Compare actual vehicle condition to below sketches/pictures and decide OK or NG.

If there is doubt about OK NG condition, judge NG and replace the tank.

OK Condition

NG Condition, Separation (Void)

NG Condition, V shape

In OK condition there is slight curvature

at mating line. And there is no sharp

edge appearance

In Separation (void) condition, there is

clear defect on the mating line. (Can only

happen on visible area from fuel pump

hole)

In V shape condition, there is sharp edge

appearance and no curvature at mating

line.



OK Condition

NG Condition, Separation (Void)

NG Condition, V shape

ts10-043 pdc new verso - fuel tank concern - check and repair procedure - attachment 2

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