Fuel System Cleaning Procedures

WARNING: Have a dry chemical (Class B) fire extinguisher near the work area.

FUEL TANK
1. Disconnect negative battery cable.
2. Relieve fuel system pressure.
3. Drain fuel tank.
4. Fuel tank.
5. Fuel sender assembly.

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

6. Flush fuel tank with hot water.

CAUTION: When flushing fuel tank, the fuel and water mixture needs to be treated as a hazardous material. The material needs to be handled in accordance with all applicable local, state, and federal laws and regulations.

7. Pour water out of fuel sender assembly opening (rock tank to be sure that removal of water from tank is complete).

In-Line Fuel Filter
- Inspect In-line fuel filter, for contamination.
- Replace the filter, if it is plugged.

Clean
Fuel lines, by applying air pressure in the opposite direction of fuel flow.

INSTALL OR CONNECT
1. New strainer (if necessary) on the fuel gage sending and pump unit.

CAUTION: Care should be taken not to fold over or twist the strainer, when installing the sending unit, as this will restrict fuel flow.

2. Fuel gage sender and pump unit, with a new seal into the fuel tank.
3. Fuel tank.
4. Disconnect the fuel feed line at the front of the vehicle.
5. Hose to the fuel feed line at the front of the vehicle and insert the end of the hose into a 3.8 liter (one gallon) fuel can.
6. Negative battery cable.
7. Twenty three liters (six gallons) of clean fuel into the fuel tank.
8. Energize fuel pump relay, to operate the fuel pump, until two liters (1/2 gallon) of fuel flows into the fuel can. This will purge the fuel pump.
9. Fuel line, at the front of the vehicle.
- Check all connections, for leaks, and tighten all hose clamps.