Fuel System Cleaning Procedure

WARNING: This procedure will NOT remove all fuel vapors. Do not attempt any repair on the fuel tank or filler neck where heat or flame is required, as an explosion resulting in personal injury could occur.

NOTE: If the fuel is contaminated, or if there is foreign material in the tank, the tank can usually be cleaned.

PROCEDURE:

1. Disconnect the negative battery cable.
2. Place a dry chemical (Class B) fire extinguisher near the work area.
3. Relieve the fuel system pressure.
4. Drain the fuel tank. See FUEL TANK DRAINING PROCEDURE.
5. Remove the fuel tank. See COMPONENT REPLACEMENT.
6. Remove the external fuel filters and inspect for contamination. If the filters are plugged, replace them.
7. Move the tank away from heat, flame or other source of ignition. Remove the fuel level sending unit and inspect the condition of the strainer. If the strainer is contaminated, install a new strainer when reassembled.
8. Complete draining the tank by rocking it and allowing the fuel to run out of the fuel pump/level sending unit tank opening.
9. Purge the fuel tank. See FUEL TANK PURGING PROCEDURE.
10. Disconnect the fuel feed pipe at the in-line filter and use air pressure to clean the fuel line. Apply air pressure in the opposite direction the fuel normally flows through the line. Disconnect the return line and apply air pressure to clean.
11. Use low air pressure to clean pipes on the fuel level sender unit assembly.
12. Install a new filter strainers on the fuel level sending unit, if required.
13. Install the modular fuel level sending unit with a new gasket into the tank and install the fuel tank. Connect the fuel level sender harness to the body harness. The fuel level lender harness must be routed below the sender unit fuel pipes. Connect all fuel lines except the feed line at the engine. Install the fuel filter.

NOTE: Care should be taken not to fold over or twist the strainer when installing the fuel level sending unit as this will restrict the flow. Also, assure that the strainer does not block the float arm full travel.

14. Connect the battery cable.
15. Turn ignition "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leak.
16. Check all connections for leaks. Tighten all hose clamps.