Fuel Delivery and Air Induction: Service and Repair
TOOLS REQUIRED^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Fuel Line Quick-Connect Separator Tool Set
REMOVAL PROCEDURE
IMPORTANT: 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the in-line fuel filter.
IMPORTANT: If filter is plugged or contaminated, replace it after cleaning fuel pipes.
4. Inspect the in-line fuel filter for contamination.
5. Drain fuel tank. Refer to Fuel Tank Draining Procedure. Procedures
6. Remove fuel tank.
7. Locate the tank in a suitable work area away from heat, flame, or other source of ignition.
8. Remove the fuel sender assembly (1) from the fuel tank (4).
9. Inspect the fuel sender strainer. If the strainer is contaminated, the strainer must be replaced and the fuel tank should be cleaned.
10. Inspect the fuel pump inlet for dirt and debris. If found, the fuel sender should be replaced.
11. Flush fuel tank with running hot water for at least five minutes.
12. Pour the water out of fuel sender assembly opening.
13. Rock the tank to be sure that removal of water from 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.
14. Disconnect the fuel feed (3) fuel return pipes (2), quick-connect fittings inside the engine compartment.
15. Remove the (1) EVAP pipe from the EVAP canister purge valve.
NOTE: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
16. Apply air pressure to fuel pipes in the opposite direction from normal fuel flow.
17. Wipe off male pipe ends. Inspect all connectors for dirt and burrs, using a clean shop towel.
18. Clean the components/assemblies as required.
19. Replace the components/assemblies as required.
INSTALLATION PROCEDURE
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 pipes.
2. Install the fuel feed return (2) fuel feed pipes (3), quick-connect fittings inside the engine compartment.
3. Remove the (1) EVAP pipe from the EVAP canister purge valve.
4. Reinstall fuel sender assembly into the fuel tank.
5. Install the fuel filter (1).
6. Reinstall the fuel tank (2).
8. Add fuel to the fuel tank.
9. Tighten the fuel filler cap.
CAUTION: Refer to Battery Disconnect Caution in Service and Precautions.
10. Connect the negative battery cable.
11. Inspect for leaks.
11.1. Turn ON the ignition for 2 seconds.
11.2. Turn OFF the ignition for 5 seconds.
11.3. Turn ON the ignition.
11.4. Check for fuel leaks.
12. Install the fuel injector sight shield (1) to the engine.
NOTE: Refer to Fastener Notice in Service and Precautions.
13. Install the fuel injector sight shield nuts (2).
Tighten
Tighten the nuts 3 N.m (27 lb in).