2004 Chevrolet Tracker 4WDFACTORY OEM SERVICE PROCEDURE

Fuel System Cleaning

IMPORTANT:
  • If a fuel system problem is caused by contaminated fuel or other foreign material in the fuel tank, the tank must be cleaned. If the tank is rusted or is still contaminated after cleaning, the tank must be replaced.
  • Only use oil free compressed air to blow out the fuel pipes.
  • Inspect the fuel tank internally and clean the fuel tank if you find a plugged fuel filter.
  1. Remove the fuel tank from the vehicle. Refer to Fuel Tank Replacement .
  2. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  3. Remove the fuel tank pressure sensor from the fuel tank. Refer to Fuel Tank Pressure Sensor Replacement .
  4. Remove the fuel cut-off valve from the fuel tank. Refer to Fuel Cut-Off Valve Replacement .
    5. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations.
  5. Fill the fuel tank with hot water.
  6. Shake the fuel tank vigorously for 5 minutes.
  7. Drain the fuel tank.
    8. IMPORTANT: If the inside of the fuel tank contains any traces of rust after cleaning, replace the fuel tank.
  8. Inspect that all of the water is removed from the fuel tank.
  9. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  10. Install the fuel tank pressure sensor to the fuel tank. Refer to Fuel Tank Pressure Sensor Replacement .
  11. Install the fuel cut-off valve to the fuel tank. Refer to Fuel Cut-Off Valve Replacement .
  12. Install the fuel tank to the vehicle. Refer to Fuel Tank Replacement .
  13. Refill the fuel tank.
    14. NOTE: Refer to Fastener Notice in Cautions and Notices.
  14. Connect the negative battery cable.

    Tighten:  Tighten the negative battery cable retainer to 8 N.m (72 lb in).

  15. Inspect for leaks and repair as necessary.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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