Fuel Delivery and Air Induction: Service and Repair

REMOVAL
- Remove the negative battery cable.
- Disconnect the engine harness connector on the distributor.

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

- Remove the fuel from the tank.
- Remove the fuel tank.
- Remove the fuel gauge and pump unit.
- Purge the fuel from the tank.
- Remove the in-line fuel filter.

INSPECTION
- Inspect in-line fuel filter, for contamination.
- Replace the fuel filter, if it is plugged.

CLEANING
- Clean fuel lines, by applying air pressure in the opposite direction of the fuel flow.

INSTALLATION
- A new fuel strainer (if necessary) on the fuel sender and pump unit.
- Install the fuel gauge and pump unit, with a new seal into the fuel tank.

NOTE: Care should be taken not to fold over or twist the strainer, when installing the sending unit, as this will restrict fuel flow.

- Install fuel tank.
- Disconnect the fuel feed line at the front of the vehicle.
- Install a hose to the fuel feed line at the front of the vehicle and insert the other end of the hose into a 3.8L (One gallon) fuel can.
- Reconnect the negative battery cable.
- Fill tank with twenty-three liters (six gallons) of clean fuel into the tank.
- Energize the fuel pump relay, to operate the fuel pump, until two liters (one half gallons) of fuel flows into the fuel can. This will purge the fuel pump.
- Reconnect the engine harness connector to the distributor.
- Check all connections, for leaks, and tighten all hose clamps.