Fuel System Cleaning Procedures

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.

WARNING:
To Reduce the Risk of Fire and Personal Injury: Do Not attempt to repair sections of nylon fuel lines. If damaged, replace. Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. If nylon fuel feed or return connecting lines become kinked, and cannot be straightened, they must be replaced. Before connecting fuel lines, always apply a few drops of clean engine oil to the male tube 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). If new fuel line is nicked, scratched or damaged during installation, it must be replaced.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure. Refer to Fuel System / Service and Repair.
2. Fuel system in-line fuel filter.
3. Drain fuel tank.
4. Fuel tank.
5. Locate tank in a suitable work away from heat, flame or other source of ignition.

Inspect
^ Contamination of in-line filter. If filter is plugged or contaminated, replace it after cleaning fuel lines.
^ 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, the fuel pump should be replaced.

6. Fuel sender assembly.
7. Flush fuel tank with running hot water for at least five minutes. Pour water out of fuel sender assembly opening, fuel filler opening, and fuel filler vent opening. (Rock tank to be sure that removal of water from tank is complete).
8. Quick connect fittings at engine compartment fuel feed and return lines.
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in quick-connect fitting. Repeat for other fittings.

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

Clean
b. Using compressed air, blow out dirt from quick-connect fittings before removing.
c. Choose correct tool from J 37088-A for size of fitting.
d. Insert tool into female end of connector, push inward and pull connector apart.
e. Repeat for other fittings.
9. Using compressed air, apply air pressure to all fuel lines in opposite direction from normal fuel flow.

CLEAN

CAUTION:
If it is necessary to remove rust or burrs from the male tube end of a quick-connect fitting: use emery cloth in a radial motion with the tube end to prevent damage to O-ring sealing surfaces.
^ Using a clean shop towel, wipe off male tube ends.
^ Inspect all connectors for dirt and burrs. Clean or replace components / assemblies as required.

WARNING: To Reduce the Risk of Fire and Personal Injury:

Before connecting fuel line fittings, apply a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings 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.
4. Fuel filter.
5. Fuel tank.

INSPECT
Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.