Fuel Delivery and Air Induction: Service and Repair

Fuel System Cleaning

Special Tools
* J 45722 Fuel Sender Lock Ring Wrench
* CH-48482 Fuel Sender Lock Ring Wrench
* J 45004 Fuel Tank Drain Hose

Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).


Note:
* 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.
* If the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.

1. Remove the fuel tank. Refer to Fuel Tank Draining (Procedures).
2. Remove the fuel module assemblies. Refer to Fuel Tank Fuel Pump Module Replacement - Right Side (Fuel Tank Fuel Pump Module Replacement - Right Side) and Fuel Level Sensor Replacement - Left Side (Fuel Level Sensor Replacement - Left Side).
3. Locate the tank in a suitable work area away from any heat, any flame, or any other source of ignition.
4. 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.

Warning

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

Note: Only use oil-free compressed air to blow out the fuel pipes.

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

Note: 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.

5. Flush the fuel tank with running hot water for at least 5 minutes. Pour the water out of the fuel sender assembly opening. Rock the tank in order to make sure that the removal of the water from the tank is complete.
6. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) to disconnect the following quick connect fittings from the fuel rail:
The feed hose/pipe

Note: Only use oil-free compressed air to blow out the fuel pipes.

7. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.
8. Remove the fuel injectors and fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
9. Clean and inspect the fuel injectors and fuel rail.

Installation Procedure

1. Assemble the fuel system as follows:
Install the fuel injectors and fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
2. Install the fuel module assemblies. Refer to Fuel Tank Fuel Pump Module Replacement - Right Side (Fuel Tank Fuel Pump Module Replacement - Right Side) and Fuel Level Sensor Replacement - Left Side (Fuel Level Sensor Replacement - Left Side).
3. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) to connect the following quick connect fittings to the fuel rail:
The feed hose/pipe
4. Install the fuel tank. Refer to Fuel Tank Replacement (Removal and Replacement).