Fuel Delivery and Air Induction: Service and Repair

WARNING: This procedure will not remove all fuel vapors. Do not attempt any repair on the tank or filler neck where heat or flame is required, as an explosion resulting in personal injury could occur. Have a Class B fire extinguisher near the work area.

NOTE: If the trouble is due to contaminated fuel or foreign material that has been put into the fuel tank, it can usually be cleaned. If the tank is rusted internally, it should be replaced.

PROCEDURE:
1. Fuel system pressure must be released prior to service.
2. Disconnect the negative battery cable.
3. Drain the fuel tank.
4. Remove the fuel tank.
5. Remove the in-line fuel filter, and inspect for contamination. If the filter is plugged, replace it. (Leave the fuel line disconnected.)
6. Move the tank away from heat, flame, or other source of ignition. Remove the fuel pump assembly and inspect the in-tank filter. If the in-tank filter is contaminated, a new in-tank filter should be installed when reassembled.
7. Complete draining the tank by rocking and allowing the fuel to run out the access hole.
8. Purge the fuel tank.
9. Use low air pressure to clean the fuel pump coil.
10. Install the fuel pump assembly into the tank.
11. Install the fuel tank. Connect the fuel pump wires and all fuel lines except the fuel line at the engine.
12. Disconnect the fuel feed hose from the chassis hose at the engine.
13. Connect a hose onto the chassis fuel hose and insert the other end into an empty 1 gallon can.
14. Connect the battery cable.
15. Put 6 gallons (23 Liters) of clean fuel in the tank and actuate the fuel pump to pump two quarts (two Liters) of fuel into the can.
This will purge any contaminated fuel from the fuel pump and lines.
16. Remove the hose and connect the fuel line to the engine. Use new clamps and/or Quick-Connect fittings where necessary.
17. Start the engine and check for leaks.