U-Haul Rental Trucks - Lack of Power, Hard Start, No Start, Poor Engine Performance (Clean Fuel Tank)

Some customers may comment on lack of power, hard starting, no start and/or poor engine performance.

The in-tank fuel strainer located on the fuel module reservoir assembly (MRA) may be restricted due to foreign material in the tank. It is possible that during the tank manufacturing process, excessive coating material was left in the fuel tank, resulting in a restricted strainer.

1. Diagnose the source of the driveability concern. Refer to Symptoms - Engine Controls (SI Document ID# 1464864).

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (C4/5) (SI Document ID# 888936).
3. Remove the fuel filler cap.
4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure (SI Document ID# 1203001).
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information SI Document ID# 827585.

Caution: 

•	Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

•	Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.

6. Place a approved suitable drain pan under the fuel tank drain plug.
7. Remove the fuel tank drain plug and drain the fuel tank. Properly dispose of the old fuel.
8. Remove the bolt and nut securing the support brace from the body to the box skirting, located just rear of the fuel tank.
9. Support the fuel tank with a suitable adjustable stand.
10. Remove the fuel tank support bracket retaining nuts located on the inside of the frame rail.
11. Lower the fuel tank enough to disconnect the fuel lines and electrical connector.
12. Disconnect the fuel and EVAP lines. Refer to Quick Connect Fitting(s) Service (Metal Collar). Refer to Quick Connect Fitting(s) Service (Metal Collar) (Document ID# 717137).
13. Disconnect the MRA electrical connector and ground wire nut.
14. Remove the fuel tank with the fuel tank support brackets from the frame rail.
15. Prior to removing the MRA, blow off the MRA area with shop air.
16. Remove the 6 nuts and washers from the MRA retaining ring.
17. Remove the MRA retaining ring.
18. Remove the MRA.
19. Remove the MRA seal from the fuel tank.



20. Inspect the MRA strainer (1) for contamination. If the strainer has a dark/dirty look or is brown/black in color, replace the inline fuel filter, remove the spark plugs and inspect for a lean fuel condition and replace the MRA.
21. Move the fuel tank to a suitable cleaning area.
22. Locate a stand or fixture suitable to support the weight of the fuel tank and water.

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.

•	Perform each wash cycle for a minimum of 2 minutes.

•	Perform the wash cycle three times.

23. Using a high pressure water spray-wand, spray all interior surfaces with clean/non-contaminated water. Be sure to spray all internal tank surfaces including fore and aft sections of tank behind baffles, while allowing water to drain out of the drain hole. Perform each wash cycle for a minimum of 2 minutes.
24. Using a high pressure air wand, dry all interior tank surfaces. Tank should be tipped accordingly to facilitate removal of water. Assure pressurized air does not contain any contaminants.
25. Repeat steps 23 and 24 for a total of 3 wash/dry cycles.
26. Hand dry tank surfaces with a white towel to confirm dryness and cleanliness.
27. Remove the old sealant from the drain plug male threads and tank drain female threads.
28. Apply a new 0.05 mm (0.002 in) thick coat of sealant, P/N 12346004 (in Canada, 10953480), or equivalent, to the drain plug male threads and tank drain female threads.
29. Notice: Refer to Fastener Notice in Cautions and Notices. Install the tank drain plug.

Tighten
Tighten the tank drain plug to 54 N·m (40 lb ft).

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the MRA gasket when reinstalling the MRA.

30. Install a new MRA O-ring seal, P/N 25166292.

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

31. Care should be taken not to fold over or twist the strainer when installing the MRA as this will restrict fuel flow.
32. Install the MRA in the fuel tank.
33. Install the MRA lock ring to the fuel tank. Make sure the lock ring alignment holes fit over the tabs on the tank .
34. Install the 6 washers and nuts retaining the MRA lock ring.

Tighten
Tighten the lock ring nuts to 8 N·m (71 lb in).

35. Position the fuel tank into place. Allow access to connect the fuel lines and electrical connectors.
36. Install the fuel tank ground wire.

Tighten
Tighten the nut to 9 N·m (79 lb in).

37. Install the fuel feed, fuel return , and EVAP lines to the MRA. Refer to Quick Connect Fitting(s) Service (Metal Collar).
38. Install the electrical connector.
39. Position the fuel tank into mounting position.
40. Install the fuel tank support bracket nuts.

Tighten
Tighten the nuts to 175 N·m (129 lb ft).

41. Install the box skirting brace bolt and nut.

Tighten
Tighten the bolt and nut to 5.6 N·m (50 lb in).

42. Lower the vehicle.
43. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (C 4/5) (SI Document ID# 888936).
44. Refill the fuel tank with clean fuel.
45. Start the vehicle.
46. Inspect for leaks.
47. Road test the vehicle.

For vehicles repaired under warranty, use:

*This labor operation is for bulletin use only.