Fuel System Cleaning Procedures

Fuel Tank Installation:

Under Car:

Engine Compartment:

FUEL SYSTEM CLEANING

TOOL REQUIRED
J 37088-A tool set, Fuel Line Quick-Connect Separator

PROCEDURE SCOPE
The following procedure covers disassembly and inspection of the complete fuel supply system. If the fuel system is contaminated, it can be cleaned. The extent of fuel system contamination can usually be determined during disassembly.

REMOVE OR DISCONNECT
1. Negative battery terminal.
2. Relieve fuel system pressure. Refer to Fuel System Pressure Relief Procedure. [1][2]Fuel System Pressure Relief Procedure
3. In-line fuel filter. Refer to Fuel Filter (In-Line) Replacement Procedure. Service and Repair

Inspect
Contamination of the in-line fuel filter. If filter is plugged or contaminated, replace it after cleaning fuel pipes.

4. Drain fuel tank. Refer to Fuel Tank Draining. Service and Repair
5. Fuel tank. Refer to Fuel Tank Replacement. Service and Repair
6. Locate tank in a suitable work area away from heat, flame or other source of ignition.
7. Modular fuel sender assembly. Refer to Modular Fuel Sender Assembly Replacement. Service and Repair

Inspect
^ Fuel sender strainer. If strainer is contaminated, it must be replaced and the fuel tank should be cleaned.
^ Fuel pump inlet for dirt and debris. If found, fuel sender should be replaced.

8. Flush fuel tank with running hot water for at least five minutes. Poor water out of fuel sender assembly opening (Rock tank to be sure that removal of water from tank is complete).

NOTICE: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced. Do not attempt to repair sections of nylon fuel pipes. If damaged, replace.

9. Quick-connect fittings at engine compartment fuel feed and return pipes:

a. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each directing to loosen any dirt in quick-connect fitting. Repeat for other fittings. Using compressed air, blow out dirt from all quick-connect fittings before removing.

CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Insert tool into female connector, then push inward to release male connector.
c. Repeat for other fitting.

10. Using compressed air, apply air pressure to fuel pipes in opposite direction from normal fuel flow.

NOTICE: If it is necessary to remove rust or burrs from the male pipe end or a quick-connect fitting, use emery cloth in a radial motion with the pipe end to prevent damage to O-ring sealing surface.

11. Using a clean shop towel, wipe off male pipe ends. Inspect all connectors for dirt and burrs. Clean or replace components]assemblies as required.

CAUTION: To Reduce The Risk Of Fire And Personal Injury:
^ Before connecting fuel pipe fittings, apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)

INSTALL OR CONNECT
1. Apply a few drops of clean engine oil to the male tube ends of the fuel feed and return engine pipes.
2. Fuel pipe quick-connect fittings:
a. Push connectors together to cause the retaining tabs/fingers to snap into place.
b. Once installed, pull on both ends of each connection to make sure they are secure.
3. Fuel sender assembly. Refer to Modular Fuel Sender Assembly Replacement.
.
4. Fuel filter. Refer to Fuel Filter (In-Line) Replacement Procedure.
5. Fuel tank. Refer to Fuel Tank Replacement.

INSPECT
Turn ignition to 'ON' position for two seconds, then turn to 'OFF' for ten seconds. Again turn to 'ON' position, and check for fuel leak.