Fuel System Cleaning Procedures

Fuel Injector Electrical Diagram:

Special Tools
Tool required: J37088-2 Fuel Pipe Separator Tool

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

1. Disconnect negative battery terminal.

2. Relieve fuel system pressure (refer to Fuel System Pressure Relief).

3. Remove in-line fuel filter (refer to In-line Fuel Filter Replacement).

Inspect
^ Contamination of the in-line fuel filter. If filter is plugged or contaminated, replace it after cleaning fuel pipes.

4. Drain fuel tank (See Draining Fuel Tank).

5. Remove fuel tank (refer to Fuel Tank Replacement).

6. Locate tank in a suitable work area away from heat, flame or other source of ignition.

7. Remove modular fuel sender assembly (refer to Fuel Tank Unit).

Inspect
^ Fuel pump strainer. If strainer is contaminated, it must be replaced and the fuel tank should be cleaned.

^ Fuel pump inlet for dirt and debris. If found, fuel pump should be replaced.

8. Flush fuel tank with running hot water for at least five minutes. Pour water out of fuel sender assembly opening (rock tank to be sure that removal of water from tank is complete).

Notice
If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.

^ Do Not attempt to repair sections of nylon fuel pipes. If damaged, replace.

9. Quick - connect fittings at engine compartment fuel feed and return pipes:

a. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick-connect fitting. repeat for other fittings.

Clean

Caution
Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

^ Using compressed air, blow out dirt from all quick-connect fittings before removing.

b. Insert tool into female connector, then push inward to release male connector.

c. Repeat for other fitting.

10. Using compressed air, apply air pressure to fuel pipes in opposite direction from normal fuel flow.

Note
If it is necessary to remove rust or burrs from the male pipe end or a quick-connect fitting, use emery cloth in a radial motion with the pipe end to prevent damage to O-rings sealing surface.

Clean

Inspect

^ Using a clean shop towel, wipe off male pipe ends.

^ Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required.

Caution
To Reduce The Risk Of Fire And Personal Injury: Before connecting fuel pipe fittings, apply a few drops of clean engine oil to the male pipe ends. 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.)

Install or Connect
1. Apply a few drops of clean engine oil to the male tube ends of the fuel feed and return engine pipes.

2. Connect fuel line quick-connect fittings:

a. Push connectors together to cause the retaining tabs/fingers to snap into place.

b. Once installed, pull on both ends of each connection to make sure they are secure.

3. Fuel sender assembly. Refer to Modular Fuel Sender Assembly - Replacement in this section.

4. Fuel filter. Refer to In-line Fuel Filter in this section.

5. Fuel tank. Refer to Fuel Tank Replacement in this section.

Inspect
a. Turn ignition to 'ON' position for two seconds, then turn to 'OFF' for ten seconds. Again turn to 'ON' position, and check for fuel leak.