Important: When flushing the fuel tank, the fuel and water mixture needs to be treated as a hazardous material. The material needs to be handled in accordance with all local, state and federal laws and regulations.

Have a dry chemical (Class B) fire extinguisher near the work area.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Remove pickup box. Refer to Pickup Box Replacement in Body Rear End.
4. Drain the fuel tank. Refer to Fuel Tank Draining .
5. Remove the fuel tank. Refer to Fuel Tank Replacement .
6. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .

•	Whenever the fuel tank is cleaned, the fuel pump strainer must be inspected. If the strainer is contaminated, replace the strainer and the fuel filter.

•	Inspect the fuel pump inlet for dirt and debris. If found, replace the fuel sender and fuel filter.

7. Flush the fuel tank with hot water.
8. Pour the water out of the fuel sender assembly opening.
9. Rock tank to be sure that removal of water from tank is complete.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Install the new strainer, if necessary, on the fuel sender assembly.
2. Install the fuel sender assembly with a new seal into the fuel tank.
3. Install the fuel tank. Refer to Fuel Tank Replacement .
4. Install pickup box. Refer to Pickup Box Replacement in Body Rear End.
5. Disconnect the fuel feed line at the front of the vehicle.
6. Connect a hose to the fuel feed line at the front of the vehicle.
7. Insert the end of the hose into a 3.8 liter (1 gallon) fuel can.
8. Connect the negative battery cable.
9. Install 23 liters (6 gallons) of clean fuel into the fuel tank.
10. Use a scan tool in order to energize the fuel pump until 2 liters (1/2 gallon) of fuel flows into the fuel can. This will purge the fuel pump.
11. Install the fuel line at the front of the vehicle.
12. Inspect for leaks through the following steps:

12.1.

Turn ON the ignition for 2 seconds.

12.2.

Turn OFF the ignition for 10 seconds.

12.3.

Turn ON the ignition.

12.4.

Inspect for fuel leaks.