Fuel System Cleaning

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure.
3. Remove the fuel tank.
4. Remove the fuel sender.

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

5. Clean the fuel tank.
6. Remove the fuel strainer or replace as necessary.
7. Disconnect the fuel feed hose from the lift pump.
8. Disconnect the fuel return line from the injection pump, using the following guidelines:
^ 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 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. 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.

IMPORTANT: Use a suitable container to catch the fuel.

7. Use the scan tool in order to command the fuel lift pump ON until clean fuel is pumped into the fuel manager.
8. Install the new fuel filter.
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. Use the scan tool in order to command the fuel lift pump ON until clean fuel appears at the return line. This process may take up to 3 minutes before clear fuel is observed.

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

11. Crack open each injection line at the nozzle. Use 2 wrenches in order to prevent nozzle damage.
12. Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears from each nozzle.

NOTE: Refer to Fastener Notice in Service Precautions.

13. Tighten the injection line.

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

14. start the engine.
15. Allow the engine to idle for 15 minutes.

IMPORTANT: Make sure that the fuel return line is in the metal container and that the container does not overflow.

16. Turn off the engine.
17. Disconnect the hose from the metal container.
18. Connect the fuel return line to the injection pump.
19. Check for leaks.
20. Clear the engine DTCs.

Gasoline in Fuel System

Engine Will Run or Start
1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Fill the fuel tank with diesel fuel.
3. Allow the engine to run for 15 minutes.

Engine Will Not Run
1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
2. Fill the fuel tank with diesel fuel.
3. Disconnect the engine shutoff solenoid connector.
4. Disconnect the fuel hose between the fuel manager/filter and the injection pump.
5. Connect a hose to the fuel manager/filter outlet and run it to a closed metal container.
6. Crank the engine for 15 seconds with one minute cooling periods in order to purge gasoline from the system.
7. Connect the fuel hose between the fuel filter and the injection pump.
8. Connect the engine shutoff solenoid connector.
9. Start the engine.
10. Run the engine for 15 minutes.
11. Check for leaks.
12. Clear the engine DTCs.