Fuel Delivery and Air Induction: Service and Repair

Fuel System Cleaning

Removal Procedure

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


Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect negative battery cable.
2. Relieve fuel system pressure, refer to Fuel Pressure Relief Service and Repair.
3. Drain fuel tank. Refer to Fuel Tank Draining Procedures.
4. Remove the fuel tank. Refer to Fuel Tank Replacement Fuel Tank Replacement.
5. Remove the fuel sender assembly using the following procedure:

* When the fuel tank is cleaned, the fuel pump strainer must be inspected. If the strainer is contaminated, replace the strainer and inspect the fuel pump.
* Inspect the fuel pump inlet for dirt and debris. If found, replace the fuel pump.

6. Flush the fuel tank with hot water.
7. Pour the water out of the fuel sender assembly opening.
8. Rock tank to be sure that removal of water from tank is complete.
Refer to Fuel Sender Assembly Replacement Service and Repair.

In-line Fuel Filter Inspection

1. Inspect the in-line fuel filter for contamination.
2. Replace the fuel filter if the filter is plugged.

Fuel Pipe Cleaning

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

Installation Procedure

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Install the new strainer on the fuel sender assembly, if necessary.
2. Install the fuel sender assembly with a new seal into the fuel tank
3. Install the fuel tank. Refer to Fuel Tank Replacement Fuel Tank Replacement.
4. Disconnect the fuel feed line at the front of the vehicle.
5. Connect a hose to the fuel feed line at the front of the vehicle.
6. Insert the end of the hose into a 3.8 liter (one gallon) fuel can.
7. Connect the negative battery cable.
8. Install 23 liters (6 gallons) of clean fuel into the fuel tank.
9. Energize the fuel pump relay (by way of the Tech 2 ) in order to operate the fuel pump, until 2 liters (1/2 gallons) of fuel flows into the fuel can. This will purge the fuel pump.
10. Install the fuel feed line at the front of the vehicle.
11. Check all the connections for leaks.
12. Tighten all the hose clamps.

Leak Test

If fuel is leaking from the tank, the tank should be replaced. Make sure that the fuel lines are not leaking onto the tank.

1. Remove the fuel tank.
2. Drain the tank.
3. Plug all of the outlets.
4. Apply 7-10 kPa (1-1.5 psi) air pressure through the vent tube.
5. Test for leaks with a soap solution or by submersion.
6. Replace the tank if a leak is found.