Water In Fuel System

REMOVAL PROCEDURE

1. Disconnect the negative battery cable(s).
2. Drain the fuel from the tank. Go to Draining Fuel Tank. Service and Repair
3. Remove the fuel tank.
4. Remove the fuel sender. Go to Fuel Tank Unit.
5. Clean the fuel tank.

NOTE: The fuel tank should be replaced if the fuel tank is rusted internally.

6. Remove the fuel strainer or replace as necessary. Go to Fuel Strainer.
7. Disconnect the fuel feed hose from the fuel lift pump.
8. 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.

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

INSTALLATION PROCEDURE
1. Install the fuel sender. Refer to Fuel Sender Assembly.
2. Install the fuel tank.
3. Install the fuel feed pipes at the fuel lift pump.
4. Add clean diesel fuel into the tank until the tank is 1/4 full.
5. Install the fuel tank cap.
6. Connect the negative battery cable.

NOTE: Use a suitable container to catch the fuel.

7. Crank the engine for 15 seconds with one minute cooling periods until the clean fuel is pumped out.
8. Install the new fuel filter. Go to Fuel Filter Element Replacement.
9. 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).
10. Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears at the return line.
11. Install the FUEL SOL fuse in the fuse panel.

- Crack open each injection line at the nozzle. Use two wrenches in order to prevent nozzle damage.
- Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears from each nozzle.

NOTE: Use two wrenches in order to prevent nozzle damage.

Tighten
Tighten the injection line to the nozzle fitting to 25 Nm (18 lb. ft.).

- Start the engine.
- Allow the engine to idle for 15 minutes.

NOTE: 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.

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