GM Service Manual Online
For 1990-2009 cars only
Table 1: Initial Fuel Injector Return Flow Values
Table 2: Retesting Fuel Injector Return Flow Values

What Fuel to Use in the United States

Notice: Use of diesel fuel other than Ultra Low Sulfur Diesel (15 ppm sulfur maximum) or engine oil other than low ash CJ-4 oil will cause permanent damage to the DPF and related components.

In the United States, for best results use Number 2-D diesel fuel year-round, above and below freezing conditions, as oil companies blend Number 2-D fuel to address climate differences. Number 1-D diesel fuel may be used in very cold temperatures when the temperature stays below -18°C (0°F). However, the fuel will produce a power and fuel economy loss. The use of Number 1-D diesel fuel in warm or hot climates may result in stalling, poor starting when the engine is hot and may damage the fuel injection system.

It is acceptable to use diesel fuel containing up to 5 percent biodiesel (B5), but the final blended fuel must meet the same specification, ASTM D 975 (Grades No. 2-D or No. 1-D S15 commonly known as Ultra Low Sulfur diesel), as the other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage could not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier.

Because of the cleansing properties of biodiesel, switching from straight diesel to a biodiesel blend can prematurely restrict the fuel filter with normal deposits in the fuel system. A fuel filter replacement might be required sooner than the recommended interval.

Diesel fuel may foam when filling the tank. This can cause the automatic pump nozzle to shut OFF, even though the tank is not full. If this happens, just wait for the foaming to stop and then continue to fill the tank.

What Fuel to Use in Canada

Canadian fuels are blended for seasonal changes. Diesel Type A fuel is blended for better cold weather starting, when it stays below -18°C (0°F). However, the fuel will produce a power and fuel economy loss. The use of Type A diesel fuel in warmer climates may result in stalling, poor starting. Diesel Type B fuel is blended for temperatures above -18°C (0°F). The emission control system requires the use of diesel fuel with ultra low sulfur, 15 ppm, content. Both low and higher sulfur fuels will be available in Canada. Only ultra low sulfur diesel fuels are available in the United States. Diesel-powered trucks must be refueled with ultra low sulfur fuel only. Use of fuels with higher-sulfur content will affect the function of the emission components and may cause reduced performance, excessive smoke and unpleasant odor.

It is acceptable to use diesel fuel containing up to 5 percent biodiesel (B5), but the final blended fuel must meet the same specification, CAN/CGSB-3.517 (ULS) in Canada, as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the latest version of ASTM specification D 6751. Biodiesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine. Higher concentration (i.e. greater than B5) biodiesel-containing fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and could damage the fuel system and engine. Such damage would not be covered by your warranty. If there are questions about the biodiesel-containing fuels you are using, contact your fuel supplier.

Very Cold Weather Operation

If the vehicle is driven in very cold temperatures and can not get a winterized Number 2-D that has been adapted to cold weather or a Number 1-D, use one gallon of kerosene for every 2 gallons of diesel fuel. Once you add kerosene, run the engine for several minutes to mix the fuels. Only add kerosene when the temperature falls below -18°C (0°F), because the fuel economy and lubricating qualities of kerosene is not as good as that of diesel fuel.

In cold weather , the fuel filter may become clogged (waxed). To unclog the filter, move the vehicle to a warm garage area and warm the filter to a temperature between 0-10°C (32-50°F). Replacing the filter is not necessary.

Fuel Specific Gravity Testing

Use a J 38641-B Diesel Fuel Quality Tester to measure the fuel specific gravity (API Rating). Follow the instructions on the tool to obtain the proper temperature-adjusted value. This information must be accurate for the proper diagnosis of the fuel system.

Fuel Injector Return Flow and Fuel Pressures

The fuel return from the fuel injectors to the tank will vary based on the API value of the fuel. Measure the Fuel API with the Diesel Fuel Quality Tester. For this reason the Fuel System Diagnosis - High Pressure Side values will vary for identifying a fuel injector or fuel pump concern. Use the following tables when referred to by the diagnostic. The first table is to be used during the initial diagnosis to identify the worst fuel injectors. After the fuel injectors that fail the first part of the test are capped off, the return flow from each uncapped fuel injector must be measured again. This is because the fuel system is returning less fuel to the tank, and thus the fuel pressure is higher during the retest. Failure to use the correct table may result in the replacement of good fuel injectors.

Initial Fuel Injector Return Flow Values

API Rating

Maximum Single Fuel Injector Return Flow

30-34

3 ml

35-39

4 ml

40-44

5 ml


Retesting Fuel Injector Return Flow Values

API Rating

Maximum Single Fuel Injector Return Flow

30-34

4 ml

35-39

5 ml

40-44

5 ml

Water in Fuel

Sometimes, water can be pumped into the fuel tank along with diesel fuel. This can happen if the service station does not regularly inspect and clean their fuel tanks, or the fuel gets contaminated for the service stations suppliers.

If water is pumped into the fuel tank, a water in fuel light will illuminate. If the water in fuel light illuminates, the excess water must be drained from the fuel system on the vehicle.