Fuel Delivery and Air Induction: Service and Repair

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.

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

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect negative battery cable.
2. Relieve the fuel system pressure.
3. Drain the fuel tank.
4. Remove the fuel tank.
5. Remove the fuel sender assembly.
- Whenever the fuel tank is cleaned, the fuel pump strainer must be inspected. If the strainer is contaminated, replace the strainer and the fuel filter.
- Inspect the fuel pump inlet for dirt and debris. If found, replace the fuel sender and fuel filter.

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.

Installation Procedure

NOTE: 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.
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 (1 gallon) fuel can.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

7. Connect the negative battery cable.
8. Install 23 liters (6 gallons) of clean fuel into the fuel tank.
9. Using a scan tool, 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:
1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Check for fuel leaks.