Fuel System Cleaning Procedures

REMOVAL PROCEDURE

Important: When flushing the 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 local, state and federal laws and regulations.

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

1. Disconnect negative battery cable.

2. Relieve fuel system pressure.

Refer to Fuel Pressure Relief Procedure.

3. Drain fuel tank.

Refer to Fuel Tank Replacement.

4. Remove the fuel tank.

Refer to Fuel Tank Replacement.

5. Remove the fuel sender assembly.

Refer to Fuel Pressure Regulator Replacement (SFI).

^ Whenever 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 sender assembly.

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.

9. Inspect the in-line fuel filter for contamination. If contaminated, replace the in-line fuel filter.


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 (if necessary) on the fuel sender assembly.

2. Install the fuel sender assembly with a new seal into the fuel tank

3. Install the fuel tank.

Refer to 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 until 2 liters (1/2 gallons) of fuel flows into the fuel can. This will purge the fuel pump.

10. Install the fuel line at the front of the vehicle.

11. Inspect for leaks through the following steps:

11.1. Turn the ignition switch ON for 2 seconds.

11.2. Turn the ignition switch OFF for 10 seconds.

11.3. Turn the ignition switch ON.

11.4. Check for fuel leaks.