Motorvac CarbonClean 1000 User manual

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 2012 MotorVac, Inc. ZIM11-00474 Rev. 0
CarbonClean1000

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 2012 MotorVac, Inc. ZIM11-00474 Rev. 0
Table of Contents
Introduction ..............................................................................................................................3
System Features and Functions...............................................................................................4
Safety Information.....................................................................................................................6
Safety Before Starting ..............................................................................................................................6
Safety When Connecting/Disconnecting Hoses.......................................................................................7
Safety During Service...............................................................................................................................7
Initial Setup................................................................................................................................8
Service Procedures...................................................................................................................9
Fuel System Types ...................................................................................................................................9
Manifold Connection..............................................................................................................................11
Vehicle Connection 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 Test......................................................................................................................23
Fuel Volume Test...................................................................................................................................23
Leakdown Test.......................................................................................................................................25
Deadhead Test........................................................................................................................................25
Troubleshooting and Additional Help.....................................................................................26
Appendix A - Maintenance......................................................................................................27
Maintenance Procedures.........................................................................................................................27
Maintenance Record...............................................................................................................................27
Appendix B - Replacement Parts............................................................................................28
Replacement Parts .................................................................................................................................28
Appendix C - System Accesories ...........................................................................................29
Standard Adaptor Kit..............................................................................................................................29
Deluxe Adaptor Kit ................................................................................................................................31

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Introduction
Congratulations on your selection of the MOTORVAC CarbonClean 1000. By choosing this
product, you are acquiring the most technologically advanced method available for cleaning
harmful fuel system contaminants from gasoline engines.
This is a self-contained cleaning system, designed to connect to any gasoline engine. Once the
unit is connected, it temporarily replaces the regular fuel supply with Fuel System Cleaner and
Engine Decarbonizer which is a proprietary mixture of fuel and a specially formulated Cleaning
Detergent.
With the engine running, the unit pumps the Fuel System Cleaner and Engine Decarbonizer
through the engine's fuel system. 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 combustion chamber creates a more even burn of fuel,
which improves horsepower, increases fuel economy, and reduces exhaust emissions.
It is recommended that you perform the fuel system cleaning procedure on a vehicle every
15,000 miles (24,000 km) to obtain the highest fuel system efficiency.
Please study this Operators Manual to become thoroughly familiar with the CarbonClean 1000
before using it.
IMPORTANT
The Fuel System Cleaner is designed to work
EXCLUSIVELY
with the MotorVac Fuel System Cleaner and Engine Decarbonizer
Use of any other chemical during this process may cause operational
failure of the machine and voids the manufacturer’s warranty.
See warranty card for details.

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System Features and Functions
11-Quick coupler
12-Service hose
13-Pressure relief/fuel system flow test
button
14-Pressure relief/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
6- Machine pressure gauge
7- Adapter tray
8- Drip cap
9- Inlet port
10-Inlet filter
Carbon Clean 1000 Front and Top
1
2
3
4
5
6
7
8, 9, 10
11
12
13
15
14

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Descriptions of the gauges, control switches, and status indicators that make up the control panel are
listed below. Please become familiar with these control panel features and functions before using the unit.
1. Air pressure regulator – Used to adjust the system pressure in the cleaning process.
2. Power light indicator – Illuminates when the power cables are connected to a 12VDC power
source.
3. Ready light indicator – Illuminates when there is fluid in the machine indicating it is ready for
the service.
4. Service complete indicator – Illuminates when the service is complete.
5. Fuel Line pressure gauge – Indicates the pressure in the vehicle’s fuel lines.
6. Machine pressure gauge– Indicates the pressure the CarbonClean 1000 is supplying 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 filter when not in use.
9. Inlet port – Accepts can and transfers the fuel system cleaner and engine decarbonizer into the
CarbonClean 1000.
10. Inlet filter – Filters debris from entering the machine and vehicle’s fuel system.
11. Quick coupler – Connects the CarbonClean 1000 to the appropriate adapter.
12. Service hose – Transfers fluid from CarbonClean 1000 to vehicle.
13. Pressure relief/fuel system flow test button – Use to relieve pressure before disconnecting the
CarbonClean 1000 from the vehicle and to perform fuel pump diagnostic flow test.
14. Pressure relief/fuel system flow test bottle – Collects fluid when relieving pressure and
performing a flow test on the vehicle’s fuel system.
15. Power cable – Connect to vehicle’s battery before performing a service.

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Safety Information
Please become familiar with all safety procedures described in this chapter.
IMPORTANT
Failure to observe these precautions, or the
improper use of equipment, could result in
property damage or serious injury.
Follow the safety procedures in this chapter each
time the unit used.
Safety Before Starting
Follow these safety procedures before starting any service with the unit.
Ventilate the Work Area.
To avoid breathing harmful fumes and exhaust, make sure the unit is always used in a well ventilated
area, away from all flames, sparks, and other ignition sources.
Keep a Fire Extinguisher On Hand.
Keep an approved fire extinguisher within easy reach.
Check Oil and Coolant Levels.
Check engine oil and 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 positive (+) battery terminal. Connect the negative (black) lead to the negative (-)
battery terminal (11-15 VOLTS DC).
Avoid Open Flames and Sparks.
Keep lighted cigarettes, open flames, or other ignition sources away from the battery.
Use Caution at All Times.
Use safety goggles and keep hands, hair, loose clothing, and jewelry away from the battery, fan blades,
belts, and other moving parts of the vehicle engine.
Ensure Vehicle is safe
Before beginning a service ensure the vehicle is in satisfactory condition (i.e. broken or loose fuel lines,
ignition wires, battery cables, electrical wires, fuses and relays.)
Relieve Fuel Tank Pressure.
Before performing any fuel system service remove or loosen the fuel filler cap to the vehicle to relieve
fuel tank pressure.

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Safety When Connecting/Disconnecting Hoses
Fuel systems maintain residual pressure in fuel lines even after the engine has been turned off.
Use caution when opening any fuel line.
Avoid Spills.
To avoid fuel spills, wrap a clean shop cloth around fittings when connecting or disconnecting any hoses
or adapters.
Remove Ignition Sources.
Remove all ignition sources such as lit cigarettes, matches, 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 manual for test procedures and fuel system specifications (i.e. fuel pressure).
Clean Spills Immediately.
Clean up all gasoline or detergent spills immediately and make sure to use a proper container for disposal.
Check All Fittings.
Check all fittings and fuel lines for leaks before, during, and after performing a cleaning service.
Secure Fuel Lines.
Keep fuel lines away from hot manifolds and all moving components.

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Initial Setup
Hardware Required
•Air hose nipple
•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” wrench to hold assembly to prevent from
turning)
Air hose
inlet port

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Service Procedure
Fuel System Types
Before beginning an exchange determine if the vehicle being serviced has a return or
returnless fuel 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
excess fuel back to the tank.
NOTE: The fuel pump must be disabled for return fuel systems as dead heading
the pump can cause damage to the pump or fuel system.

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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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Manifold Connection
The CarbonClean 1000 has been developed with a special manifold block to simplify
services as well as increase diagnostic capabilities. When servicing a vehicle with 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 fuel pump side of the manifold.
Caution: When servicing a vehicle with a returnless fuel system refer to
manufacturer’s service procedures when deadheading a fuel pump to ensure the
fuel pump cannot be damaged.

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Vehicle Connection Procedure
1. With the vehicle’s engine off remove the vehicle’s gas cap.
2. Connect air supply hose to air inlet adapter on the back of the CarbonClean
1000.
3. Turn pressure regulator counterclockwise until the machine pressure gauge
reads zero.
4. Connect the CarbonClean1000 to the vehicle. Refer to application guide for
instructions on how to properly connect to the vehicle 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.
Wear Safety goggles.
Obtain ZERO pressure before connecting or disconnecting any fuel lines or adaptors.
Wear chemical resistant gloves when connecting or disconnecting fittings and
adaptors.
Wrap shop towel around pressure fittings and adaptors when disconnecting.
Avoid exposure to flames, sparks, hot engine parts, and other ignition sources.
Explosion or flame or exposure to flammable liquid and vapors
can cause injury.

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Service Procedure With Manifold Connection
1. Open both ball valves on manifold assembly. The system is now in bypass.
2. Connect the CarbonClean 1000 supply hose to the manifold.
3. Start vehicle and inspect for any leaks 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
diagnostic features can now be used to evaluate fuel system performance if
desired. See diagnostic section 5 of this manual.
5. Run the vehicle between 1700 and 2000 rpm to warm up the engine and catalytic
converter to normal operating temperature.

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6. Remove dust cap. Attach can by screwing it to the inlet port. Refer to directions
on the can. Observe the sight glass below the inlet port to ensure the can fully
empties into the machine. Leave can on during service.
7. Connect the CarbonClean 1000 battery terminals to the car’s battery. The power
and ready LEDs should be illuminated.
8. Set the pressure on the CarbonClean 1000 by turning the pressure regulator
clockwise slowly until the MACHINE PRESSURE GAUGE reads 5-10 psi below the
pressure noted in step 4.
CAUTION: Refer to application guide for vehicle specific instructions.
9. Close the fuel pump ball valve on the manifold assembly 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 LED is illuminated the
treatment is complete. Shut off the engine. Disconnect the unit’s battery clips.
CAUTION: Relieve pressure in the fuel line before disconnecting adapters.
11.The pressure can be relieved by doing the following. Turn air pressure regulator
counter-clockwise until the machine pressure gauge reads zero. Press and hold
the 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.
NOTE: Use only approved
chemicals
Use of non approved chemicals
can be a serious fire/explosion
hazard
Do not leave machine
unattended during service.

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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
flow test button

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Service Procedure With Schrader Port Connection
1. Connect the CarbonClean 1000 supply hose to the adapter mounted on the
Schrader port.
2. Start vehicle and inspect for any leaks at Schrader port 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 be used to evaluate fuel system performance if
desired. See diagnostic section 5 of this manual.
4. Run the vehicle between 1700 and 2000 rpm to warm up the engine and catalytic
converter to normal operating temperature.

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5. Remove dust cap. Attach can by screwing it to the inlet port. Refer to directions
on the can. Observe the sight glass below the inlet port to ensure the can fully
empties into the machine. Leave can on during service.
6. Connect the CarbonClean 1000 battery terminals to the car’s battery. The power
and ready LEDs should be illuminated.
7. Set the pressure on the CarbonClean 1000 by turning the pressure regulator
clockwise slowly until the MACHINE PRESSURE 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 instructions.
9. When the buzzer sounds and the amber Service Complete LED is illuminated the
treatment is complete. Shut off the engine. Disconnect the unit’s battery clips.
Turn air pressure regulator counter-clockwise until the machine pressure gauge
reads zero.
CAUTION: Relieve pressure in the fuel line before disconnecting adapters.
NOTE: Use only approved
chemicals
Use of non approved chemicals
can be a serious fire/explosion
hazard
Do not leave machine
unattended during service.

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10.The pressure can be relieved by doing the following. Turn air pressure regulator
counter-clockwise until the machine pressure gauge reads zero. Press and hold
the 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 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
flow test button

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Service Procedure 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 mounted directly to the fuel line.