This procedure checks for the presence of water and gasoline
in the diesel fuel that may cause the injection pump and the nozzle to incur
damage.
- Remove the fuel filter element.
- Inspect the fuel filter element.
• | If water, gasoline or fungi/bacteria are not present, end the
inspection. |
• | If water or fungi/bacteria are present, refer to Fuel System Cleaning
. |
• | If gasoline is present, refer to Fuel System Cleaning
. |
- Cleaning the water from the Fuel System.
• | Disconnect the batteries. |
• | Remove the fuel tank. Refer to Fuel Tank Replacement
. |
• | Remove the fuel sender unit. Refer to Fuel Sender Assembly Replacement
. |
• | Inspect the fuel tank and the fuel sender for rust, fungi or bacteria. |
• | Clean the inside of the fuel tank and the fuel sender with hot
water. |
• | Dry the fuel tank and the fuel sender with compressed air. |
• | Disconnect the ends of the following lines. |
- | The lift pump suction line |
- | The lift pump feed line |
- | The fuel filter outlet line |
- | The fuel filter drain line |
• | Inspect each of the pipes and replace any rusted pipes. |
• | Clean the inside of the fuel filter housing. |
• | Dry the inside of the fuel filter housing with compressed air. |
• | Dry the inside of each line with low pressure air. |
• | Remove the FUEL SOL fuse from the fuse panel. |
• | Install a new fuel filter element. |
• | Install the fuel sender and the fuel tank (add clean diesel fuel
to ¼ full). |
• | Reconnect the following lines. |
- | The lift pump suction (both ends) lines |
- | The lift pump feed (both ends) lines |
- | The fuel filter drain line |
- | The fuel return (at injection pump) line |
• | Connect the fuel filter outlet and the fuel return line at the
fuel sender to the hoses that flow to the metal containers. |
• | Use the Scan Tool in order to command the lift pump ON. |
• | Operate the lift pump until the clean fuel flows from the fuel
filter outlet into a metal container. |
• | Connect the hose from the fuel filter outlet to the injection
pump inlet. |
• | Open each injection line at each nozzle end. |
• | Crank the engine until the clean fuel flows from it. |
- | Use two wrenches when loosening the injection line fittings. |
- | Allow a maximum of 15 seconds cranking time, followed by 1 minute
of cranking motor cooling time. |
• | Use two wrenches in order to tighten each injection line fitting
at its nozzle. |
• | Install the FUEL SOL fuse in the fuse panel. |
• | Allow the engine to run for 1 minute while the fuel flows from
the fuel return line into a metal container. |
• | Connect the fuel return hose to the fuel sender. |
• | Clean the engine of fuel spillage. |
• | Fill the fuel tank and add a biocide, if needed. |
- Cleaning Gasoline from the Fuel System.
4.1. | Drain the fuel tank. |
4.3. | Remove the FUEL SOL fuse from the fuse panel. |
4.4. | Remove the fuel filter outlet. |
4.5. | Connect the fuel filter outlet to a hose that flows to a metal
container. |
4.6. | Use a Scan Tool in order to command the lift pump ON until the
clean fuel flows from the fuel filter outlet into a metal container. |
4.7. | Connect the hose from the fuel filter outlet to the injection
pump inlet. |
4.8. | Install the FUEL SOL fuse in the fuse panel. |
4.9. | Attempt to start and run the engine for 15 minutes (If the engine
does not start, purge the injection system). |
4.11. | Clean the engine of fuel spillage. |
4.12. | Clear the engine DTC(s). |