Fuel Delivery and Air Induction: Service and Repair
TOOLS REQUIRED^ SA9127E-7 Fuel Flow/Pressure Adapter
After it is determined that the fuel system is contaminated, the following procedure to clean it is recommended:
CAUTION: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist provide additional support for the vehicle on the opposite end from which components are being removed.
1. Place vehicle on hoist and open hood.
CAUTION: Any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
2. Disconnect negative battery cable.
CAUTION: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place. Any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
3. Drain fuel tank. (Refer to "Fuel Tank Draining" procedure.) Procedures
4. Remove fuel tank.
5. Disconnect fuel feed and return line at fuel rail.
6. With compressed air, blow out fuel feed and return lines. Catch fuel in a container at opposite end of the line.
7. Remove EVAP canister from fuel tank.
8. Remove pump module.
9. Inspect inlet filter on pump. If plugged or damaged, fuel pump module must be replaced not serviced separately.
10. Flush tank with hot water for at least 6 minutes; invert and drain. All metal chips/debris must be removed from tank prior to installation.
11. Install EVAP canister to fuel tank.
12. Install fuel pump module to fuel tank using new fuel pump seal. Do not connect fuel feed line to new filter.
13. Install fuel tank to vehicle.
NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected at fuel filter and fuel rail. Install new retainer into female portion of connection. Care must be taken to assure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
14. Connect fuel lines to fuel rail.
15. Put at least six gallons of clean fuel into fuel tank.
16. Connect negative battery cable.
17. Connect Scan tool to vehicle and turn ignition On.
18. Raise vehicle on hoist and (1) install 3/8 in. male quick connect adapter (from fuel flow/pressure adapter SA9127E-7) into fuel feed line.
19. Install drain hose to adapter and place other end in an approved container.
20. Energize fuel pump with Scan tool for 1 to 2 minutes. (Refer to "Energizing the Fuel Pump" procedure.) This will pump about two quarts of fuel and purge any debris in fuel pump.
NOTE: Replace plastic fuel line retainers whenever fuel supply lines are disconnected at fuel filter and fuel rail. Install new retainer into female portion of connection. Care must be taken to assure that locking tab is centered in window of female connection. Firmly press male and female portions together until a "click" is heard, then pull firmly back to confirm engagement.
21. Disconnect fuel drain hose adapter at fuel feed line and connect fuel line to fuel filter.
22. Energize fuel pump and check all connections for leaks.
23. De-energize pump, lower vehicle, and start engine.
24. Perform "Service Bay Diagnostic Test" for evaporative emission system using Scan tool. This test will verify the integrity of vapor handling areas of fuel system.