Water In Fuel

Remove or Disconnect:
1. Battery cables
2. Fuel from the tank.
3. Fuel tank
4. Fuel gage sending unit

Clean:
- Fuel tank
- The tank should be replaced if it is rusted internally
- The pick-up filter, replace if necessary
- The check valve assembly

5. Main fuel hose at the fuel pump

6. Fuel return line at the injection pump
- Using low air pressure, force air through the lines and toward the rear of the vehicle
- Replace the pipes if they are rusted internally

7. Fuel injection pump shut-off solenoid wire
8. Fuel filter

Install or Connect:
1. Fuel gage sending unit
2. Fuel tank
3. Fuel lines to tank
4. Clean diesel fuel into the tank until it is 1/4 full
5. Fuel tank cap
6. Fuel hoses to the fuel pump

7. Battery cables
- Crank the engine for 15 seconds at a time, with one minute cooling periods, until clean fuel is pumped out
- Use a suitable container to catch the fuel

8. New fuel filter
9. A hose from the return line at the fuel injection pump to a closed metal container with a capacity of at least 8L (2 gal)

HPCA Connector:

- If the engine temperature is above 52°C (125°F), activate the HPCA (Housing Pressure Cold Advance) on the injection pump. This can be done by disconnecting the two lead connectors at the engine temperature switch and bridging the connector with a jumper wire.
- Crank the engine for 15 seconds at a time, with one minute cooling periods, until clean fuel appears at the return line.

10. Two lead connectors to the engine temperature switch
- Remove the jumper wire
- Disconnect the lead to the HPCA solenoid (on the injection pump)
- Crack open each injection line at the nozzle. Use two wrenches to prevent nozzle damage.
- Crank the engine for 15 seconds at a time, with one minute cooling periods, until clean fuel appears from each nozzle.

11. HPCA lead to the injection pump

Tighten:
- Injection line to nozzle fitting to 25 Nm (20 ft lbs)
- Use two wrenches to prevent nozzle damage

12. Fuel injection pump shut-down solenoid wire
- Start the engine and allow it to idle for 15 minutes
- 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

13. Fuel return line to the injection pump
- Check for leaks