Purging Water From Fuel System
- Disconnect negative battery cable. Remove fuel filler cap. Place hand operated pump into fuel filler neck and drain fuel from fuel tank. Reinstall fuel filler cap. Remove fuel tank and fuel sending unit assembly. Replace fuel tank if internally rusted. Replace fuel strainer (as necessary).
- Remove fuel feed hose at fuel pump. Remove fuel return line at injection pump. Using low air pressure, blow out fuel lines toward rear of vehicle. Replace fuel lines if internally rusted. Remove ECM 1 fuse. Remove fuel manager/filter element.
- Install fuel sending unit assembly and fuel tank. Install fuel feed hose to fuel pump. Fill fuel tank with diesel fuel until tank is 1/4 full. Install fuel filler cap. Reconnect negative battery cable. Crank engine for 15 seconds. Allow starter to cool down for one minute between cranking intervals. Use suitable container to collect fuel. Repeat procedure until clear fuel is pumped out.
- Install NEW fuel filter element. Connect a hose from fuel injection pump return line to a closed metal container with 2 gallon capacity. Crank engine for 15 seconds. Allow starter to cool down for one minute between cranking intervals. Repeat procedure until clear fuel is observed at fuel return line.
- Install fuse. Crack open each injection line at each nozzle. Crank engine for 15 seconds. Allow starter to cool down for one minute between cranking intervals. Repeat procedure until clear fuel is observed at each nozzle. Install injection line to nozzle fitting and tighten to specification. See TORQUE SPECIFICATIONS .
- Start engine and idle for 5 minutes. Ensure fuel return line is in metal container and container does not overflow. Turn ignition off. Remove hose from metal container. Install fuel return line to injection pump. Check for leaks.