Fuel Delivery and Air Induction: Service and Repair

REMOVAL
1. Remove the negative battery cable.
2. Disable the engine spark system to prevent accidental starting.
^ Have a dry chemical (Class B) fire extinguisher near the work area.
3. Remove the fuel from the tank.
4. Remove the fuel tank.
5. Remove the fuel gauge and pump unit.
6. Purge the fuel from the tank.
7. Remove the fuel filter.

INSPECTION
^ Inspect fuel filter for contamination.
^ Replace the fuel filter, if it is plugged.

CLEAN
Clean fuel lines, by applying air pressure in the opposite direction of the fuel flow.

INSTALLATION
1. A new fuel strainer (if necessary) on the fuel sender and pump unit.
2. Install the fuel gauge and pump unit, with a new seal into the fuel tank.
NOTE: Care should be taken not to fold over or twist the strainer, when installing the sending unit, as this will restrict fuel flow.
3. Install fuel tank.

FLUSH: (FUEL INJECTED MODELS)
1. Disconnect the fuel feed line at the front of the vehicle.
2. Install a hose to the fuel feed line at the front of the vehicle and insert the other end of the hose into a 3.8L (One gallon) fuel can.
3. Reconnect the negative battery cable.
4. Fill tank with twenty-three liters (six gallons) of clean fuel into the tank.
5. Energize the fuel pump relay, to operate the fuel pump, until two liters (one half gallons) of fuel flows into the fuel can. This will purge the fuel pump.
6. Reconnect the engine harness connector to the distributer.

CHECK:
1. Check all connections, for leaks, and tighten all hose clamps.