Fuel System Cleaning

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Remove the negative battery cable(s).
2. Remove the fuel from the tank.
3. Remove the fuel tank.
4. Remove the fuel sender.
5. Clean the fuel tank.

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

6. Remove the fuel strainer or replace if necessary.
7. Remove the fuel feed hose at the fuel lift pump.
8. Remove the fuel return line at the injection pump.
^ Use low air pressure to blow out the lines toward the rear of the vehicle.
^ Replace the pipes if they are rusted internally.
9. Remove the ECM 1 fuse from the underhood relay center.
10. Remove the fuel filter.

INSTALLATION PROCEDURE
1. Install the fuel sender.
2. Install the fuel tank.
3. Install the fuel feed pipes at the fuel lift pump.
4. Install clean diesel fuel into the tank until it is 1/4 full.
5. Install the fuel tank cap.
6. Install the negative battery cables.
7. Crank the engine for 15 seconds with one minute cooling periods until the clean fuel is pumped out.

IMPORTANT: Use a suitable container to catch the fuel.

8. Install a new fuel filter.
9. Install 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 ECM 1 fuse in the underhood relay center.
^ Crack open each injection line at the nozzle. Use two wrenches to prevent nozzle damage.
^ Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears from each nozzle.

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: Use two wrenches to prevent nozzle damage.

^ Retighten the injection line fittings.

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

^ Start the engine and allow it to idle for 15 minutes.

IMPORTANT: 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.

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