Disassembly

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.

Tools Required
J37088 Fuel Line Quick-Connect Separator Tool Set

Removal Procedure

Notice: Numbers in text correspond to numbered components in image.

1. Disconnect the negative battery terminal.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Release.

In-Line Fuel Filter:

3. Remove the in-line fuel filter. Refer to Fuel Filter / Service and Repair.

4. Inspect the in-line fuel filter for contamination. If filter is plugged or contaminated, replace it after cleaning fuel pipes.

Fuel Tank And Fuel Supply Lines:

5. Drain fuel tank (1). Refer to Fuel Tank / Service and Repair.

6. Remove fuel tank. Refer to Fuel Tank / Service and Repair.

7. Locate the tank in a suitable work area away from heat, flame or other source of ignition.

Fuel Tank With Modular Fuel Sender Assembly:

8. Remove the modular fuel sender assembly (4). Refer to Fuel Sender Assembly / Service and Repair.

Fuel Sender Strainer:

9. Inspect fuel sender strainer. If strainer is contaminated, it must be replaced and the fuel tank should be cleaned.

10. Inspect the fuel pump inlet for dirt and debris. If found, fuel sender should be replaced.

11. Flush fuel tank with running hot water for at least five minutes.

12. Pour water out of fuel sender assembly opening.

13. Rock the tank to be sure that removal of water from tank is complete.

Important: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.

Engine Compartment Fuel Lines:

14. Remove the fuel feed (1) and fuel return (2) at engine compartment. If necessary, remove the (3) EVAP Pipe.

Caution: Wear safety glasses when using compressed air because flying dirt particles may cause eye injury.

15. Grasp both ends of the fuel feed pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick connect fittings.





16. Blow out dirt from quick connect fittings, using compressed air.





17. Squeeze plastic tabs of male end connector of fuel filter.





18. Pull connection apart.





19. Grasp both ends of one fuel return pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick connect fittings.


Caution: Wear safety glasses when using compressed air because flying dirt particles may cause eye injury.

20. Blow out dirt from quick connect fittings, using compressed air.

21. Squeeze plastic tabs of male end connector of fuel filter.

22. Pull connection apart.

23. Insert J 37O88 tool into female connector, then push inward to release male connector. Repeat for other fitting.

Notice: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

24. Apply air pressure to fuel pipes in the opposite direction from normal fuel flow.

25. Wipe off male pipe ends using a clean shop towel. Inspect all connectors for dirt and burrs.

26. Clean components/assemblies as required.

27. Replace components/assemblies as required.