Fuel Tank Draining Procedure
CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE.FUEL TANK DRAINING
For any operation requiring removal of the fuel tank, there should be no more than three gallons of fuel remaining. This minimizes the weight of the assembly and eases handling. The fuel level can be determined by reading the fuel level gauge: a reading below 1/4 full indicates that no more than three gallons remain.
USING THE FUEL PUMP
Using the fuel pump to drain the tank is the easiest procedure if the pump is operable. The fuel can be pumped out with the vehicle on the ground or on the hoist.
On The Ground
1. Remove air cleaner inlet tubing from throttle body.
NOTICE: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.
2. Relieve pressure in fuel pressure at fuel pressure test port (refer to "Fuel Pressure Release Procedure").
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR REMOVED, WRAP A SHOP CLOTH AROUND THE FITTING AND HAVE AN APPROVED CONTAINER AVAILABLE TO COLLECT ANY FUEL.
3. Disconnect fuel feed line at fuel rail and install adapter fitting SA309738 into fuel line.
CAUTION: NEVER DRAIN OR STORE FUEL IN AN OPEN CONTAINER DUE TO THE POSSIBILITY OF FIRE OR EXPLOSION.
4. Connect suitable fuel hose to adapter fitting and connect other end of hose to certified fuel handling cart.
5. Connect Scan tool to vehicle and turn ignition On.
6. Energize the fuel pump using the Scan tool (refer to "Energizing Fuel Pump").
7. Pump out all fuel (or until no more than 1/4 tank remains).
On The Hoist
1. Remove air cleaner inlet tubing from throttle body.
NOTICE: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relived before servicing the fuel system.
2. Connect SCAN tool to vehicle diagnostic connector, turn ignition On.
3. Relieve pressure in fuel system at fuel pressure test port.
4. Raise vehicle on hoist to comfortable working height, keeping SCAN tool outside of vehicle and accessible from under car.
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR REMOVED, WRAP A SHOP CLOTH AROUND THE FITTING AND HAVE AN APPROVED CONTAINER AVAILABLE TO COLLECT ANY FUEL.
5. Disconnect fuel feed line at inlet to filter/regulator (5/16 in. line).
6. Install 5/16" x 1/4" quick connect 1 adapter from flow/pressure adapter (SA9127E-7) into fuel feed line, connect suitable drain hose to other end of adapter, and connect drain hose to certified fuel handling cart
7. Energize the fuel pump using the SCAN tool (refer to "Energizing the Fuel Pump").
8. Pump out all fuel (or until no more than 1/4 tank remains).
FUEL PUMP IS INOPERATIVE
If the fuel pump is inoperative, the tank can be drained by siphoning from the tank. A suitable means is through the fuel filler pipe with the "correct" type and stiffness of tubing as used with the SA9804E siphon hose assembly.
CAUTION: DO NOT ATTEMPT TO INSERT ANY OTHER TYPE OF SIPHON HOSE OR TUBE INTO THE FUEL FILLER PIPE. THE DESIGN OF THE INLET CHECK VALVE AT THE END OF THE FUEL FILLER TUBE (SEE "FUEL INLET CHECK VALVE"IN THIS SECTION) RESTRICTS THE INSERTION OF A HOSE AND, MOST IMPORTANTLY PREVENTS THE REMOVAL OF THIS HOSE. IF THE SIPHON HOSE BECOMES STUCK IN THE CHECK VALVE, THE FUEL FILLER PIPE WILL NOT BE ABLE TO BE REMOVED FROM THE FUEL TANK WITHOUT DAMAGE TO THE FILL PIPE OR FUEL TANK.
1. Disconnect the negative battery cable.
2. Open fuel filler door and remove gas cap.
3. Insert siphon hose guide/funnel into fuel filler pipe.
4. Insert siphon hose (SA9804E) into guide funnel and into fuel filler pipe. Some resistance may be encountered when the tip of the siphon hose reaches the inlet check valve. Repeated probing may be necessary to slide the hose tip through the check valve cage.
IMPORTANT: The siphon hose will reach the bottom of the tank within about 10 inches of the end fitting (and tag). When connecting the siphon hose to another length of hose connected to the fuel drain tanker: DO NOT insert the siphon hose into the fill pipe funnel past the tag at the fitting end. If inserted too far, the upper portion of the siphon hose may pass through the check valve cage and then jam on attempted removal.
5. Begin the fuel siphoning process.
NOTICE: The fuel flow rate from the siphon hose will range from 0.3 gal/min up to 1.0 gal/min (depending on whether it is gravity siphoned or with an air-powered pump).
6. Remove siphon hose from fuel filler pipe after draining is complete.