Removal Procedure
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.
- Disconnect
the negative battery cable(s).
- Drain the fuel from the tank. Refer to
Fuel Tank Draining
.
- Remove the fuel tank.
- Remove the fuel sender. Refer to
Fuel Sender Assembly Replacement
.
- Clean the fuel tank.
Important: The fuel tank should be replaced if the fuel tank is rusted internally.
- Remove the fuel strainer or replace as necessary.
- Disconnect the fuel feed hose from the fuel lift pump.
- Disconnect the fuel return line from the injection pump.
• | Use low air pressure in order to blow out the lines toward the
rear of the vehicle. |
• | Replace the pipes if they are rusted internally. |
- Remove the fuel filter. Refer to
Fuel Filter Element Replacement
.
Installation Procedure
- Install the fuel sender. Refer to
Fuel Sender Assembly Replacement
.
- Install the fuel tank.
- Install the fuel feed pipes at the fuel lift pump.
- Add clean diesel fuel into the tank until the tank is ¼
full.
- Install the fuel tank cap.
- Connect the negative battery cable.
- Using the scan tool activate the fuel lift pump until the clean
fuel is pumped out.
Important: Use a suitable container to catch the fuel.
- Install the new fuel filter. Refer to
Fuel Filter Element Replacement
.
- Connect 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).
- Using the scan tool activate the fuel lift pump until the clean
fuel is pumped out of the return.
• | Crack open each injection line at the nozzle. Use two wrenches
in order to prevent nozzle damage. |
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.
• | Crank the engine
for 15 seconds with one minute cooling periods until clean fuel appears
from each nozzle. |
Tighten
Tighten the injection line to the nozzle fitting to 25 N·m
(18 lb ft).
| Important: Use two wrenches in order to prevent nozzle damage.
|
• | Allow the engine to idle for 15 minutes. |
| Important: Make sure that the fuel return line is in the metal container and that
the container does not overflow.
|
• | Disconnect the hose from the metal container. |
- Connect the fuel return line to the injection pump.
- Check for leaks.
- Clear the engine DTCs.
Gasoline in Fuel System
Engine Will Run or Start
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Fill the fuel tank with diesel fuel.
- Allow the engine to run for 15 minutes.
Engine Will Not Run
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Fill the fuel tank with diesel fuel.
- Disconnect the engine shutoff solenoid connector.
- Disconnect the fuel hose between the fuel manager/filter and the
injection pump.
- Connect a hose to the fuel manager/filter outlet and run it to
a closed metal container.
- Crank the engine for 15 seconds with one minute cooling
periods in order to purge gasoline from the system.
- Connect the fuel hose between the fuel filter and the injection
pump.
- Connect the engine shutoff solenoid connector.
- Start the engine.
Important: Check for leaks.
- Run the engine for 15 minutes.
- Clear the engine DTCs.