Disassembly

Tools Required

^ J 34730-1A Fuel Pressure Gauge

^ J 37088 Fuel Line Quick-Connect Separator Tool Set

REMOVAL PROCEDURE

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

1. Relieve the fuel system pressure. Refer to Fuel Pressure Release / Service and Repair / Fuel Pressure Relief Procedure.






2. Remove the in-line fuel filter. Refer to In-Line Fuel Filter Replacement.

IMPORTANT: If filter is plugged or contaminated, replace it after cleaning fuel pipes.

3. Inspect the in-line fuel filter for contamination.

4. Drain fuel tank. Refer to Fuel Tank Draining Procedure.






5. Remove fuel tank. Refer to Fuel Tank Replacement.

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






7. Remove the modular fuel sender assembly (1) from the fuel tank (4). Refer to Refer to Fuel Tank Unit / Service and Repair / Fuel Sender Assembly Replacement.






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

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

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

11. Pour the water out of fuel sender assembly opening.

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






NOTICE: Do not attempt to straighten the kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

13. Remove the quick-connect fittings at the engine compartment fuel feed (2) and return pipes (3). Refer to Fuel Line Coupler / Service and Repair for Quick Connect Fitting(s) Service (Metal Collar).

14. Remove the (1) [1][2]EVAP pipe if necessary. Refer to EVAP System Cleaning.






CAUTION: Wear safety glasses when us in g compressed air in order to prevent 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 the quick connect fittings.






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






17. Insert tool J 37088-A into female connector, then push inward to release the male connector.






18. Pull the connection apart.

19. Repeat steps 14 through 18 for the other fitting.

NOTICE: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

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

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

22. Clean the components/assemblies as required.

23. Replace the components/assemblies as required.