Fuel Delivery and Air Induction: Service and Repair

Fuel System Cleaning

Caution: Refer to Gasoline/Gasoline Vapors Caution.

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

1. Remove the fuel filter.
2. Inspect the fuel system for contamination of the in-line fuel filter. Replace the filter after cleaning the fuel lines if the filter is plugged or contaminated.
3. Remove the fuel module assemblies.
4. Locate the tank in a suitable work area away from any heat, any flame, or any other source of ignition.
5. Perform the following procedures:

* Inspect the fuel sender strainer. Replace the primary fuel tank module if the strainer is contaminated.
* Inspect the secondary fuel tank module for debris. Clean the secondary fuel tank module if debris is found.

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

* Use compressed air in order to apply air pressure to the transfer tube.

Important: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local, state, and federal laws and regulations.

6. Flush the fuel tank with running hot water for at least five minutes. Pour the water out of the fuel sender assembly opening. Rock the tank in order to ensure that the removal of the water from the tank is complete.
7. Refer to Quick Connect Fitting Service - Metal Collar in order to disconnect the following quick connect fittings from the fuel rail:

* The feed hose/pipe
* The return hose/pipe Quick Connect Fitting Service - Metal Collar

8. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.
9. Remove the fuel injectors and fuel rail.
10. Clean and inspect the fuel injectors and fuel rail.

Installation Procedure

Assemble the fuel system as follows:

1. Install the fuel injectors and fuel rail.
2. Install the fuel module assemblies.
3. Install the fuel filter.
4. Refer to Quick Connect Fitting Service - Metal Collar in order to connect the following quick connect fittings to the fuel rail:

* The feed hose/pipe
* The return hose/pipe Quick Connect Fitting Service - Metal Collar