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: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the in-line fuel filter. Refer to Fuel Filter Replacement .
3. 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.
4. Drain the fuel tank. Refer to Fuel Tank Draining .
5. Remove the fuel tank. Refer to Fuel Tank and Evaporation Emission Canister Replacement .
6. Locate the tank in a suitable work area away from any heat, any flame, or any other source of ignition.
7. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
8. Perform the following procedures:

•	Inspect the fuel sender strainer. If the strainer is contaminated, replace the strainer and clean the fuel tank.

•	Inspect the fuel pump inlet for debris. Replace the fuel pump if 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.

Notice: 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. Disconnect the engine compartment fuel supply 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.

Reassemble the fuel system as follows:

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Connect the engine compartment fuel rail supply and return lines onto the fuel rail.

Tighten
Tighten the lines to 15 N·m (11 lb ft).

2. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
3. Install the fuel filter. Refer to Fuel Filter Replacement .
4. Install the fuel tank. Refer to Fuel Tank and Evaporation Emission Canister Replacement .
5. Crank the engine for a few seconds. Turn OFF the engine if the engine starts.
6. Check for any fuel leaks.