Fuel Delivery and Air Induction: Service and Repair

REMOVAL PROCEDURE

Have a dry chemical Class B fire extinguisher near the work area.

CAUTION: Refer to battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the 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.
^ Whenever you clean the fuel tank, you must inspect the fuel pump strainer. If the strainer is contaminated, replace the strainer.
^ Inspect the fuel pump inlet for debris. If you find debris, replace the sender assembly.
6. Flush the fuel tank with hot water.
7. Pour the water from the fuel sender assembly opening.
8. Rock the tank in order to ensure that the removal of water from the tank is complete.

CLEANING AND INSPECTION PROCEDURE
1. Inspect the in-line fuel filter for contamination.
2. If the filter is plugged, replace the fuel filter.
3. Clean the fuel lines by applying air pressure in the opposite direction of the fuel flow.

INSTALLATION PROCEDURE

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

1. Install the fuel sender assembly with a new seal into the fuel tank.
2. Install the fuel tank.
3. Disconnect the fuel feed line at the front of the vehicle.
4. Connect a hose to the fuel feed line at the front of the vehicle.
5. Insert the end of the hose into a 3.8 liter (1 gallon) fuel can.
6. Connect the negative battery cable.
7. Install 23 liters (6 gallons) of clean fuel into the fuel tank.
8. Using the scan tool, energize the fuel pump until 2 liters (1/2 gallons) of fuel flows into the fuel can. This procedure will purge the fuel pump.
9. Install the fuel line at the front of the vehicle.
10. Check all connections for leaks.
11. Tighten all the hose clamps.