Fuel Delivery and Air Induction: Service and Repair

CAUTION: Refer to Gasoline/Gasoline Vapors Caution in Service Precautions.

TOOLS REQUIRED
J 42374 Fuel Line Quick-Connect Separator Tool Set

The following procedure covers the disassembly and the inspection of the complete fuel supply system. If the fuel system is contaminated, the fuel system can be cleaned. You can usually determine the extent of the fuel system contamination during the disassembly.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery terminal.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Remove the in-line fuel filter.
4. Inspect the fuel system for contamination of the in-line fuel filter.
Replace the filter after cleaning the fuel lines if the filter is plugged or contaminated.
5. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
6. Remove the fuel tank.
7. Locate the tank in a suitable work area away from any heat, any flame or any other source of ignition.
8. Remove the fuel sender assembly.
^ Inspect the fuel sender strainer. If strainer is contaminated, you must clean the strainer and clean the fuel tank.
^ Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if dirt or debris is found.
9. Flush the fuel tank with running hot water for at least five minutes. Pour the water out of the fuel sender assembly opening (Rock the tank in order to ensure that the removal of the water from the tank is complete).

NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

10. Remove the engine compartment fuel feed and return lines.

CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.

11. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.

INSTALLATION PROCEDURE

NOTE: Remove rust or burrs from the engine compartment fuel pipes using the following procedure:

1. Use emery cloth in order to remove rust or burrs from a fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
2. Use a clean shop towel in order to wipe off the male tube ends.
3. Inspect all the connectors for dirt and burrs. Clean or replace the components and assemblies as required.

Reassemble the fuel system as follows:

CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings in order to reduce the risk of fire and personal injury.

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 tube ends of the fuel feed and return engine lines.
2. Install the engine compartment fuel feed and return lines onto the fuel rail.
3. Install the fuel sender assembly.
4. Install the fuel filter.
5. Install the fuel tank.
6. Crank the engine for a few seconds. Turn off the engine if the engine starts.
7. Check for any fuel leaks.