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.
8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2
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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.
8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2
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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.
8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2
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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
8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2
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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.
8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2
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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.
8/3/2019 TS10-043 PDC New Verso - Fuel Tank Concern - Check and Repair Procedure - Attachment 2
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OK Condition
NG Condition, Separation (Void)
NG Condition, V shape