Fuel Delivery and Air Induction: Service and Repair

Fuel System Cleaning

1. Ignition OFF.

Warning:
Refer to Battery Disconnect Warning Battery Disconnect Warning.


2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).

Warning:
Refer to Safety Glasses Warning Safety Glasses Warning.


Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


Warning:
Refer to Relieving Fuel Pressure Warning Service Precautions.


Warning:
Refer to Safety Glasses and Compressed Air Warning Safety Glasses and Compressed Air Warning.


3. Relieve the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.

Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.





Note:
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. The extent of the contamination can be determined during the disassembly procedure.

5. Detach the fuel feed line connector (1) and inspect for contamination. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

6. Remove the fuel tank if contamination is found. Refer to Fuel Tank Replacement Removal and Replacement.

7. Remove the fuel tank module assemblies. Refer to:

* Primary Fuel Tank Module Replacement Primary Fuel Tank Module Replacement

* Secondary Fuel Tank Module Replacement Secondary Fuel Tank Module Replacement

8. Place the fuel tank in a suitable work area away from any heat or any source of ignition.

9. Perform the following procedures:

* Inspect the primary fuel tank module for contamination. Replace the primary fuel tank module if contamination is found.

* Do not replace the primary fuel level sensor. Clean the primary level sensor with hot water.

* Inspect the secondary fuel tank module for contamination. Clean the secondary fuel tank module with hot water if contamination is found.

* Inspect the transfer tube for contamination. Clean the transfer tube with compressed air.

Note:
The fuel and water mixture is a hazardous material. Observe local, state, and federal laws and regulations when discarding hazardous materials.

10. Flush the fuel tank with hot water.

Note:
Make sure that all the water is removed from the fuel tank after the fuel tank has been cleaned from all contamination.

11. Pour the water out of the fuel tank at the fuel tank module openings by rocking the fuel tank several times.





12. Detach the fuel feed pipe (1) from the fuel feed line.

13. Clean the fuel feed lines with compressed air.

14. Remove the fuel injectors and fuel rails. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.

15. Clean the fuel injectors and fuel rails with compressed air.

16. Inspect the fuel injectors. Replace damaged fuel injectors.

Installation Procedure

1. Install the fuel tank module assemblies. Refer to:

* Primary Fuel Tank Module Replacement Primary Fuel Tank Module Replacement

* Secondary Fuel Tank Module Replacement Secondary Fuel Tank Module Replacement

2. Install the fuel tank. Refer to Fuel Tank Replacement Removal and Replacement.

3. Install the fuel injectors and fuel rails. Refer to Fuel Injection Fuel Rail Assembly Replacement Service and Repair.





4. Install the fuel feed pipe (1) to the fuel feed line.

5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) Battery Negative Cable Disconnection and Connection (Primary)Battery Negative Cable Disconnection and Connection (Auxiliary) Battery Negative Cable Disconnection and Connection (Auxiliary).