I recently detect a problem with a barely noticeable fuel leak under the tank. AFAIK, there are two potential leakage points that need to be repaired/resealed - quick release coupling and electrical line plastic barrel. Fortunately, both parts have replaceable o-rings so I decided to give it a shot. Due to greater resistance to chemicals and heat, I chose replacement Viton o-rings instead of standard nitrile rubber and silicone o-rings.
I took the opportunity to replace the cable sleeve that was damaged due to the gasoline leak. I used a high quality Teflon/PTFE silicone coated fiberglass sleeve 6mm which is a bit bulkier than the original but should be more adequate for this application.
Together with the cable sleeve, I also replaced the fuel pump connector with new AMP superseal connector and crimped new terminals because I noticed that the old terminals were inadequately crimped at the factory (torn wire seals) as you will see in the photos.
Tools and parts used:
- Pin punch (for punching out plastic barrel holding el. line)
- Circlip pliers (seeger)
- O-ring lube
- Viton o-rings (10x2 mm)
- AMP superseal 4 way connector + terminals
- Teflon/PTFE sleeve
- New quick release coupling (AP8104192, 1072003 FORD)
Photo 1 - Initial state, two points of leakage, destroyed cable sleeve
[You must be registered and logged in to see this image.]Photo 2 - Circlip removed, electrical line plastic barrel pinched out
[You must be registered and logged in to see this image.]Photo 3 - New Viton o-rings in place. Greased liberally and put back together, taking care not to pinch the o-rings.
[You must be registered and logged in to see this image.]Photo 4 - Removed quick release coupling grub screw
[You must be registered and logged in to see this image.]Photo 5 - Removed quick release coupling and fuel pump electrical connector
[You must be registered and logged in to see this image.]Photo 6, 7 - Clearly visible damage to the silicone o-ring (due to long-term exposure to gasoline?)
[You must be registered and logged in to see this image.]Photo 8 - Inadequately crimped terminals at the factory and torn wire seals
[You must be registered and logged in to see this image.]Photo 9 - New quick release coupling (AP8104192, 1072003 FORD) and Viton o-rings
[You must be registered and logged in to see this image.]Photo 10 - Installed new quick release coupling, grub screw tightened back with a few drops of Loctite 542 (resistant to fuel)
[You must be registered and logged in to see this image.]Photo 11 - New cable sleeve slipped on, new terminals crimped
[You must be registered and logged in to see this image.]Photo 12 - New terminals crimped
[You must be registered and logged in to see this image.]Photo 13, 14 - ALL DONE!
[You must be registered and logged in to see this image.]Photo 15 - Parts used
[You must be registered and logged in to see this image.]
Faruk