Kits | Suggested Tools | Skill Level(1) |
---|---|---|
61100187 | Safety Glasses, Torque Wrench |
Verify that all contents are present in the kit before installing or removing items from vehicle. | |||||
---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
1 | 1 | Fuel tank locking filler assembly w/gasket | 61000630 | ||
2 | 1 | Lockset, unkeyed (Includes items 4-6, 8) | Not sold separately | ||
3 | 1 | Clamp, hose | 29379-08 | ||
4 | 1 | Cylinder sub-assembly | Not sold separately | ||
5 | 10 | Tumbler spring | Not sold separately | ||
6 | 24 | Tumbler | Not sold separately | ||
7 | 3 | Cable strap | 10006 | ||
8 | 1 | Grease (not shown) | Not sold separately | Kluber Lubrication:
|
1. | See Figure 2. Remove tank console (1). a. Remove screws (2). | |
2. | See Figure 3. Remove existing fuel cap. a. Cut hose clamp that secures vapor hoses to fuel cap. b. Cut cable straps that secures connector (5) to vent lines. c. Disconnect connector (5) from vehicle harness. d. Disconnect vapor hoses (3). e. Remove screws (1). Retain. |
1 | Tank console |
2 | Screw (3) |
1 | Screws (6) |
2 | Fuel cap assembly |
3 | Vapor hose (2) |
4 | Vapor hose connection (2) |
5 | Connector |
1. | See Figure 4. On Original Equipment (OE) vehicle key, determine cut depth at each key station. | |
2. | Write values into Table 3. | |
3. | Refer to Table 3. Write key depth codes from Figure 4 based on cut depths measured. NOTE Cut depth codes to be second digit of tumble numbers. a. Stations 8,5,4,1: These stations use tumbler #11-14. b. Stations 7,6,3,2: These stations use tumbler #21-24. | |
4. | See Figure 5. Install tumbler springs (5), see Figure 1 , into holes at stations 8,5,4 and 1 on side (A) of cylinder sub-assembly. NOTE Place a piece of tape or hold installed tumbler springs and tumblers with a finger to hold spring and tumblers in place before installation of springs and tumbler on opposite side of cylinder sub-assembly. | |
5. | See Figure 5. Install tumblers (6), see Figure 1 , #11-14 in stations 8,5,4 and 1 per tumble numbers determined in Table 3. | |
6. | See Figure 5. Install tumbler springs (5), see Figure 1 , into holes at stations 2,3,6 and 7 on side (B) of cylinder sub-assembly. | |
7. | See Figure 5. Install tumblers (6), see Figure 1 , #21-24 in stations 2,3,6 and 7 per tumble numbers determined in Table 3. | |
8. | See Figure 6. While holding tumblers fully in place, install key in assembled cylinder sub-assembly. | |
9. | Verify that all tumblers are assembled correctly. NOTE When key is fully inserted, all eight tumblers should be flush with outer diameter of cylinder. Note tumblers that are not flush. If tumbler is high on the spring side, replace with next higher number tumbler. If tumbler is high on the opposite side, replace with next lower number tumbler. | |
10. | Apply an even layer of grease around outer diameter of tumbler area. |
A | Tumbler Station |
1 | 15.55 mm (.612 in) |
2 | 14.45 mm (.569 in) |
3 | 12.35 mm (.486 in) |
4 | 11.25 mm (.443 in) |
5 | 9.15 mm (.360 in) |
6 | 8.05 mm (.317 in) |
7 | 5.95 mm (.234 in) |
8 | 4.85 mm (.191 in) |
B | Cut Depths |
0.15 mm (.006 in) = Depth code 1 | |
0.75 mm (.030 in) = Depth code 2 | |
1.45 mm (.057 in) = Depth code 3 | |
2.25 mm (.089 in) = Depth code 4 |
1 | Cylinder sub-assembly |
2 | Tumblers, installed and flush |
3 | Key |
1. | See Figure 7. If cap is latched before lock cylinder is installed, use screwdriver or other tool to press slider inside cap's lock hole while pulling cap up. | |
2. | See Figure 8. Use screwdriver or other tool, press in locking tab (1) fully in order to properly seat lock cylinder. | |
3. | See Figure 9. Orientate lock cylinder notch (1). | |
4. | Push cylinder fully into fuel cap. | |
5. | Release locking tab. | |
6. | While continuing to push cylinder in, turn key back and forth slightly until locking tab fully extends and cylinder is latched. NOTE When turning key actuates the locking tab, it is acceptable to close cap and remove key. | |
7. | See Figure 3. Install oval locking fuel cap assembly (2) with OE screws (1). | |
8. | See Figure 10. Torque screw in sequence. Tighten. Torque: 2.8–3.3 N·m (25–29 in-lbs) | |
9. | See Figure 1. Install hose clamp (3) on vapor hose where OE clamp was removed earlier. | |
10. | See Figure 3. Connect vapor hoses (3). | |
11. | See Figure 3. Connect connector (5) to vehicle harness. a. Secure to vent lines with cable straps. | |
12. | See Figure 2. Install tank console. a. Secure with OE screws. Tighten. Torque: 3–4 N·m (27–35 in-lbs) |
Station | Side | Measured Depth | Depth Code | Tumbler No. |
---|---|---|---|---|
1 | A | 1__ | ||
2 | B | 2__ | ||
3 | B | 2__ | ||
4 | A | 1__ | ||
5 | A | 1__ | ||
6 | B | 2__ | ||
7 | B | 2__ | ||
8 | A | 1__ |