Motorvac CarbonClean 1000 User Manual Download Page 11 | Manualshive

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2012 MotorVac, Inc.

10

Returnless Fuel System

A returnless fuel system has only one fuel line going from the fuel tank to the fuel rail.
They can have the pressure controlled by either a mechanical pressure regulator or
electronically by a PCM.  Excess fuel does not pass through the fuel rail and engine
compartment.

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Summary of Contents for CarbonClean 1000

Page 1: ...2012 MotorVac Inc ZIM11 00474 Rev 0 CarbonClean1000...

Page 2: ......

Page 3: ...onnection Procedure 12 Service Procedure With Manifold 13 Service Procedure With Schrader Port Connection 16 Service Procedure with Direct Connection 19 Fuel System Diagnostics 22 Fuel System Pressure...

Page 4: ...m As the mixture passes through the vehicle s fuel system it loosens and dissolves accumulated deposits which then pass harmlessly out through the exhaust system Removing contaminants from the combust...

Page 5: ...ef fuel system flow test bottle 15 Power cable Carbon Clean 1000 Back 1 Air pressure regulator 2 Power light indicator 3 Ready light indicator 4 Service complete light indicator 5 Fuel pressure gauge...

Page 6: ...g to the vehicle during a service 7 Adapter tray Contains the adapters necessary to connect the CarbonClean 1000 to the vehicle s fuel system 8 Drip cap Stops contaminants from entering the inlet filt...

Page 7: ...coolant levels and add oil or coolant if necessary Check Polarity Always use proper polarity on battery posts When connecting the unit to a battery connect the positive red battery lead to the positiv...

Page 8: ...s etc when working with fuels and detergents Safety During Service Follow these safety instructions whenever the unit is being operated Consult Manufacturers Service Manual Use manufacturer s service...

Page 9: ...le 9 16 15mm and 1 26mm wrenches Air Line Inlet Port Apply Teflon tape or pipe thread sealant to the threads of the air hose nipple Screw the air hose nipple into the inlet port and tighten USE a 1 wr...

Page 10: ...system Return Systems A return system has 2 fuel lines one from the fuel tank to the fuel rail and one returning to the fuel tank A regulator maintains the correct fuel rail pressure by returning any...

Page 11: ...s fuel system has only one fuel line going from the fuel tank to the fuel rail They can have the pressure controlled by either a mechanical pressure regulator or electronically by a PCM Excess fuel do...

Page 12: ...h a returnless fuel system you can connect the manifold assembly inline with the vehicle s fuel line The vehicle s fuel system can then be disabled by simply closing the ball valve connected to the fu...

Page 13: ...being serviced www motorvacapplicationguide com 5 Go to next service procedure step based on connection method Flammable Liquid can squirt out of pressurized lines when connecting or disconnecting Wea...

Page 14: ...s at the manifold connections 4 Note the vehicle fuel line pressure as indicated on the fuel line pressure gauge as it is required to set the machine pressure for the service Carbon Clean 1000 diagnos...

Page 15: ...ly to disable the vehicle s fuel supply The engine is now running on the fuel system treatment Allow the engine to run until the alarm sounds 10 When the alarm sounds and the amber Service Complete LE...

Page 16: ...c 15 12 Remove adapters from the fuel lines and reconnect the vehicles fuel lines Start engine and ensure there are no leaks and the lines have not become kinked or damaged Pressure relief fuel system...

Page 17: ...adapter 3 Note the vehicle fuel line pressure as indicated on the fuel line pressure gauge as it is required to set the machine pressure for the service Carbon Clean 1000 diagnostic features can now b...

Page 18: ...GAUGE reads 5 10 psi below the pressure noted in step 4 CAUTION Refer to application guide for vehicle specific instructions 8 Disable the fuel pump See application guide for vehicle specific instruc...

Page 19: ...flow test button on the back of the CarbonClean 1000 This will lower the pressure by purging the excess fluid into the flow test bottle mounted on the back of the machine 11 Remove adapters from the...

Page 20: ...cedure with Direct Connection 1 Ensure that vehicle is at proper operating temperature before performing an exchange 2 Turn off the vehicle and connect the CarbonClean 1000 supply hose to the adapter...

Page 21: ...reads 5 10 psi below the pressure noted in the application guide CAUTION Refer to application guide for vehicle specific instructions 6 Disable the fuel pump See application guide for vehicle specific...

Page 22: ...flow test button on the back of the CarbonClean 1000 This will lower the pressure by purging the excess fluid into the flow test bottle mounted on the back of the machine 9 Remove adapters from the f...

Page 23: ...able of performing the following tests 1 Fuel system pressure test 2 Fuel system flow test 3 Leakdown test 4 Deadhead pump pressure test returnless systems only do not use on Ford Follow the vehicle c...

Page 24: ...m Flow Test 1 Turn the regulator counterclockwise to set the machine pressure to zero 2 Open both valves on the manifold 3 Start the vehicle s engine and check connections for leaks 4 While the engine...

Page 25: ...0 95 1 14 1 32 1 51 3 6 0 61 0 79 0 98 1 17 1 36 1 59 3 8 0 64 0 87 1 06 1 29 1 51 1 7 4 0 0 68 0 91 1 14 1 36 1 59 1 82 4 2 0 72 0 95 1 17 1 40 1 67 1 89 4 4 0 76 0 98 1 25 1 48 1 74 1 97 4 6 0 76 1...

Page 26: ...naturally aspirated and forced induction cars were used to estimate values indicated on the chart below Leakdown Test 1 Turn the regulator counterclockwise to set the machine pressure to zero 2 Open...

Page 27: ...vice time is 12 18 minutes depending on the engine Longer than normal service time verifies the machine was already full Inspect for leaks at next service If problem persists contact technical support...

Page 28: ...ent or similar product to keep the cabinet looking new 2 Check the cabinet for dents or impact markings Check all hoses and wires for cuts or frays Maintenance Record Use the following table to keep a...

Page 29: ...98820220 5 Adapter Tray 010 5641 6 Wheel 98064967 7 Hub Cap 98064965 8 Washer 98071135 9 Drip Cap 98820500 10 Splash Guard 98820110 11 Washer and Seal 10 pk 201352 6 7 8 9 11 10 12 Quick Coupler 9882...

Page 30: ...nClean 1000 Adaptor Part Quantity Description 063 1311 1 Spring Lock Disconnect Tool Ford 063 1360 1 Manifold Block Assembly 063 1361 1 Adapter 7 16 Female Thread 90 063 1362 1 Adapter 5 16 Female Thr...

Page 31: ...mm Quick Connect Male 063 1370 1 Adapter 10 mm Quick Connect Female 063 1371 1 Adapter Ford 9 16 Quick Connect Male 063 1372 1 Adapter Ford 9 16 Quick Connect Female 98820648 1 Replacement Retaining C...

Page 32: ...Adapter Male 14mm x 1 5 063 1318 1 Adapter Female 14mm x 1 5 063 1322 1 Adapter Male Banjo Bolt M10 x 1 0 063 1373 1 Adapter Male Banjo Bolt M12 x 1 25 063 1374 1 Adapter Male Banjo Bolt M12 x 1 5 06...

Page 33: ...1345 1 Relay Honda Fuel Pump Disable 063 1378 1 Adapter Hyundai 16 mm Male 063 1353 1 Fuel Nut Honda 063 1354 1 Adapter GM S Bend 7 16 Female Thread ORDERING PARTS Parts for the CarbonClean 1000 may...

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