Fuel System Cleaning: Notes

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 and inspection of the fuel system components.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027)  or Fuel Pressure Relief (Without CH 48027) .
2. Remove the in-line fuel filter. Refer to Fuel Filter Replacement .
3. Inspect the in-line fuel filter for contamination. Replace the filter after cleaning the fuel lines if the filter is plugged or contaminated.
4. Remove the fuel tank. Refer to Fuel Tank Replacement .
5. Remove the primary and secondary fuel module assemblies. Refer to Primary Fuel Tank Module Replacement  and Secondary Fuel Tank Module Replacement .
6. Locate the tank in a suitable work area away from any heat, any flame, or any other source of ignition.
7. Perform the following procedures:
   • Inspect the primary fuel module strainer. Replace the primary fuel tank module if the strainer is contaminated.
   • Inspect the secondary fuel tank module for debris. Clean the secondary fuel tank module if debris are found.
   WARNING: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
   • Use compressed air in order to apply air pressure to the transfer tube.
NOTE: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local, state, and federal laws and regulations.
8. 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.
9. Disconnect the fuel feed hose/pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
10. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.
11. Remove the fuel injectors and fuel rail. Refer to Fuel Injector and Fuel Rail Replacement .
12. Clean and inspect the fuel injectors and fuel rail.