Fuel System Cleaning Service OJT / Practice DTOG Proficiency Exam Date: Trainee: Trainer: Service Center: Fuel System Cleaning Service 1. Start Service Action / Behavior Call/Response Rating Wear proper Personal Protective Equipment Protective gloves recommended, but nitrile gloves may be worn Safety glasses with side shields or goggles Dark colored work shoes with slipresistant soles and oil-resistant uppers Gather the necessary tools Fuel system apparatus Container that is hung from hood Hose that drains fluid into engine Gauge to monitor vacuum Sight glass to monitor flow of fluid Other tools Flathead screwdriver Needle-nose pliers or hose-clamp tool Shop towels DTOG Fuel System Cleaning Service 1
1. Start Service (continued) Action / Behavior Call/Response Rating Inspect apparatus Inspect hose for wear or damage from heat Make sure bleed hole is free from blockage Ensure that small hole at top of container is free from blockage Ensure that thumb-screw valve is closed Inspect O-ring that seals the container to apparatus Ensure that pickup tube is secured to apparatus Make sure work area is well ventilated If possible, perform service outside If service is in bays and bay doors must be closed, attach an exhaust hose to vent exhaust outside 2. Prepare the vehicle Action / Behavior Call/Response Rating Secure hood with hood prop if necessary Best Practice - Use hood prop in all services with vehicles that have spring or piston props Check under hood area for any unusual conditions Locate and check a vacuum hose and clamp Commonly used location is the PCV valve Locate and check cap to fuel tank DTOG Fuel System Cleaning Service 2
3. Install Step 1 Cleaner to Engine Action / Behavior Call/Response Rating Carefully hang apparatus on open hood Use hook to hang apparatus Verify that thumb-screw valve on apparatus is closed Fill applicator bottle with Step 1 cleaner Attach applicator bottle to the apparatus Disconnect hose to engine Use hose-clamp pliers or needle-nose pliers to remove clamp on hose Be careful when handling hose because they can break if they are mishandled Attach hose from apparatus to connection at engine Do not allow any part of applicator to touch battery Make sure all parts of applicator and all personal and clothing items are clear of all moving engine belts and parts. Make sure applicator hose does not dangle into dangerous location Prepare area before starting engine Verify hose - Is connected to engine's induction system Free from all rotating equipment Away from hot engine parts Inspect work area to remove any loose items under the hood Make sure exhaust is properly vented Start the engine Allow engine to idle Call/Response Service Specialist: Clear to start, Bay #? LBT: Clear to start, Bay #. Service Specialist: Starting, Bay #? LBT: Thank you, Bay #. DTOG Fuel System Cleaning Service 3
3. Install Step 1 Cleaner to Engine (continued) Check vacuum gauge Make sure there is a vacuum If gauge does not move, either - Hose is not attached correctly, or Hose is not attached engine intake Must be corrected before proceeding Open thumb-screw valve on apparatus to allow fluid to drip Action / Behavior Call/Response Rating Normal to hear vacuum leak Adjust flow to fastest drip rate without a steady stream of fluid Monitor gauge and sight glass Gauge should show 5 inhg Adjust thumb screw to maintain steady drip rate Flow rate changes during service and must be monitored continually When fluid stops dripping, turn off engine Fluid will slow to slow drip or foam will appear in sight glass Test whether any fluid remains Momentarily plug bleed hole If fluid flows, adjust to fast drip When applicator is empty, turn engine off DTOG Fuel System Cleaning Service 4
4. Run engine to circulate cleaners Action / Behavior Call/Response Rating Reattach engine hose Detach apparatus hose from connection to engine Reattach engine hose with clamp Remove apparatus from hood Wipe off any spilled fluid Pour contents of Step 2 cleaner into fuel tank Start engine Idle engine for 1-2 minutes If Service Engine light illuminates, reset it Engine should be off Call/Response Service Specialist: Clear to start, Bay #? LBT: Clear to start, Bay #. Service Specialist: Starting, Bay #? LBT: Thank you, Bay #. 5. Perform quality inspection and complete service Action / Behavior Call/Response Rating Check hose connections for leaks Engine should be running Shut off engine Lower hood Check that cap to fuel tank is tight Place used shop towels in proper container Clean apparatus and return to storage Clean and replace tools DTOG Fuel System Cleaning Service 5