1. Remove the negative battery cable(s). Refer to

   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.

   .
2. Remove the fuel from the tank. Go to Fuel Tank Draining .
3. Remove the fuel tank.
4. Remove the fuel sender. Go to Fuel Sender Assembly Replacement .
5. Clean the fuel tank.

Important: The fuel tank should be replaced if it is rusted internally.

6. Remove the fuel strainer or replace if necessary. Go to Fuel Strainer Replacement .
7. Remove the fuel feed hose at the fuel lift pump.
8. Remove the fuel return line at the injection pump.

•	Use low air pressure to blow out the lines toward the rear of the vehicle.

•	Replace the pipes if they are rusted internally.

9. Remove FUEL SOL from fuse panel.
10. Remove the fuel filter. Go to Fuel Filter Element Replacement .

1. Install fuel sender. Go to Fuel Sender Assembly Replacement .
2. Install fuel tank.
3. Install fuel feed pipes at fuel lift pump.
4. Install clean diesel fuel into the tank until it is ¼ full.
5. Install fuel tank cap.
6. Install negative battery cable.
7. Crank the engine for 15 seconds with one minute cooling periods until clean fuel is pumped out.

Important: Use a suitable container to catch the fuel.

8. Install new fuel filter. Go to Fuel Filter Element Replacement .
9. Install a hose from the return line at the fuel injection pump to a closed metal container with a capacity of at least 8 liters (2 gallons).
10. Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears at the return line.
11. Install FUEL SOL fuse in fuse panel.

•	Crack open each injection line at the nozzle. Use two wrenches to prevent nozzle damage.

•	Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears from each nozzle.

Tighten
Tighten the injection line to nozzle fitting to 25 N·m (18 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Use two wrenches to prevent nozzle damage.

•	Start the engine and allow it to idle for 15 minutes.

Important: Make sure the fuel return line is in the metal container and that the container does not overflow.

•	Remove the hose from the metal container.

12. Install the fuel return line to the injection pump.
13. Check for leaks.
14. Clear engine DTCs.

Engine Will Run or Start

1. Drain the fuel tank. Go to Fuel Tank Draining .
2. Fill the fuel tank with diesel fuel.
3. Run the engine for 15 minutes.

Engine Will Not Run

1. Drain the fuel tank. Go to Fuel Tank Draining .
2. Fill the fuel tank with diesel fuel.
3. Disconnect the engine shutoff solenoid connector.
4. Remove the fuel hose between the fuel manager/filter and the injection pump.
5. Connect a hose to the fuel manager/filter outlet and run it to a closed metal container.
6. Crank the engine for 15 seconds with one minute cooling periods to purge gasoline from the system.
7. Install the fuel hose between the fuel filter and the injection pump.
8. Connect the engine shutoff solenoid connector.
9. Start the engine.

Important: Check for leaks.

10. Run the engine for 15 minutes.
11. Clear the engine DTCs.