Fuel Delivery and Air Induction: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
^ J 34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.

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

2. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel tank.
5. Remove the fuel sender assembly.
6. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump. Refer to Fuel Strainer Replacement.
7. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.

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

8. Flush the fuel tank with hot water.
9. Pour the water out of the fuel sender assembly opening.
10. Rock the fuel tank to be sure that removal of water from tank is complete.
11. Inspect the in-line fuel filter for contamination.
12. Replace the fuel filter if the filter is plugged.

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

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

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

14. Install the fuel sender assembly with a new seal into the fuel tank.
15. Install the fuel tank.
16. Connect the negative battery cable.
17. Install 23 liters (6 gallons) of clean fuel into the fuel tank.
18. Inspect for leaks.
18.1. Turn ON the ignition switch for 2 seconds.
18.2. Turn OFF the ignition switch for 10 seconds.
18.3. Turn ON the ignition switch.
18.4. Inspect for fuel leaks.