Part 3 of 3
FUEL SYSTEM PRESSURE RELIEF PROCEDURE^ Engines Without Fuel Pressure Connection (J Car Only)
^ Must Be Performed Before Disconnecting Fuel Line Fittings
CAUTION:
^ To reduce the risk of fire and personal injury, it is necessary to relieve fuel system pressure before disconnecting fuel line fittings.
^ After relieving system pressure, a small amount of fuel may be released when disconnecting fuel line fittings. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is completed.
1. Ignition "OFF."
2. Loosen fuel filler cap to relieve tank pressure,
3. Remove fuel pump fuse.
4. Start and run engine until fuel supply remaining in fuel pipes is consumed. Engage starter for 3.0 seconds to assure relief of any remaining pressure.
5. Ignition "OFF."
6. Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engine.
7. Fuel line fittings are now safe for servicing.
8. Perform service required.
^ If performing fuel pressure check with a gage equipped with a bleed hose, fuel pressure can be relieved through the gage following test. Place bleed hose into approved gasoline container and open valve to bleed system pressure.
9. Tighten fuel filler cap.
10. Ignition "OFF."
11. Connect negative battery cable.
12. Install fuel pump fuse.
13. Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks.
SERVICING QUICK-CONNECT FITTINGS
^ In order to install fuel system diagnostic equipment on vehicles equipped with plastic quick-connect fittings, fuel line separator tools must be used to disconnect the fittings. Using the separator tools to release the fittings will cause the plastic retainer to remain inside the female connector allowing diagnostic equipment to be connected.
Tools required:
J 37088-A tool set, fuel line quick-connect separator;
J 39504 tool set, fuel line quick-connect separator (restricted access)
Remove or Disconnect
1. Relieve fuel system pressure (see "Fuel Pressure Relief").
2. If equipped, slide dust cover back to access quick-connect fitting.
3. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within fitting.
CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.
4. Using compressed air, blow dirt out of fitting.
5. Choose correct tool from 4 37088-A or 4 39504 tool set for size of fitting. Insert tool into female connector, then push/pull inward to release locking tabs.
6. Pull connection apart.
Clean and Inspect
NOTICE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to O-ring sealing surface.
^ Using a clean shop towel. wipe off male pipe end.
^ Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.
Install or Connect
CAUTION: To Reduce the Risk of Fire and Personal Injury:
^ Before connecting fitting, always apply a few drops of clean engine oil to the male pipe end of engine fuel pipe, pressure gage adapter or fuel line shut-off adapter. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)
1. Apply a few drops of clean engine oil to the male pipe end of engine fuel pipe, pressure gage adapter or fuel line shut-off adapter.
2. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make sure connection is secure.
4. If equipped, reposition dust cover over quick-connect fitting.