Diesel Fuel System Contamination

DIESEL FUEL SYSTEM CONTAMINATION

NOTE: Fuel system damage that was caused by incorrect or contaminated fuel that was introduced into the fuel system by the customer is not covered under warranty.

IF THE ENGINE WAS NOT STARTED AFTER INCORRECT OR CONTAMINATED FUEL WAS USED DURING REFUELING

If the fuel system has been contaminated (with gasoline, water, etc.) AND the engine WAS NOT STARTED, the following procedure must be followed:

1. Remove all fuel from the fuel tank. Draining Fuel Tank Use an appropriate fuel container. Dispose of the contaminated fuel using the proper procedures.

CAUTION: Dispose of petroleum based products in a manner consistent with all applicable Local, State, Federal, and Provincial regulations.

2. Remove the fuel tank. Fuel Tank - Removal
3. Ensure the swirl pot indentation below the in the fuel tank electric fuel pump inlet is completely drained of any contaminated fuel.
4. Completely drain the low pressure fuel lines, and install a new fuel filter.
5. Install the fuel tank, and fill with clean diesel fuel.
6. Road test the vehicle to verify normal operation.

IF THE ENGINE WAS STARTED AFTER INCORRECT OR CONTAMINATED FUEL WAS USED DURING REFUELING

If the fuel system has been contaminated (with gasoline, water, etc.) AND the engine WAS STARTED, the following procedure must be followed:

1. Remove all fuel from the fuel tank. Draining Fuel Tank Use an appropriate fuel container. Dispose of the contaminated fuel using the proper procedures.

CAUTION: Dispose of petroleum based products in a manner consistent with all applicable Local, State, Federal, and Provincial regulations.

2. Remove the fuel tank. Fuel Tank - Removal
3. Ensure the swirl pot indentation below the in the fuel tank electric fuel pump inlet is completely drained of any contaminated fuel.
4. Completely drain the low pressure fuel lines, and install a new fuel filter.
5. Install the fuel tank, and fill with clean diesel fuel.
6. Detach the low pressure line at the T-Fitting orifice between the fuel injector low pressure return lines and the fuel filter
7. Connect a clean hose to the T-Fitting orifice, and place the other end in a suitable clean container.
8. Turn the ignition ON, and collect the fuel escaping from the T-Fitting orifice in a clean container. Check the fuel sample for metal chips, dirt, or other foreign matter.
9. If any dirt or metal chips are present in the fuel sample, completely clean the high pressure side of the fuel injection system, then install new the fuel injectors, and the high pressure fuel pump.
10. If there are no metal chips or dirt present in the fuel sample, the fuel system is ok. Reconnect the T-Fitting orifice, and road test the vehicle to verify normal operation.