This procedure checks for the presence of water and gasoline in diesel fuel that may cause injection pump and nozzle damage.

Remove the fuel filter element and inspect it.

1. If water, gasoline or fungi/bacteria are not present, end the inspection.
2. If water or fungi/bacteria are present, Go to Cleaning Water from Fuel System.
3. If gasoline is present, Go to Cleaning Gasoline from Fuel System.

1. Disconnect the batteries.
2. Drain the fuel tank.
3. Remove the fuel tank. (Refer to Fuel Tank Replacement).
4. Remove the fuel sender unit. (Refer to Fuel Sender Replacement).
5. Inspect the fuel tank and fuel sender for rust, fungi or bacteria. Clean the inside of the fuel tank and fuel sender with hot water, then dry them with compressed air.
6. Disconnect the ends of the following lines.

6.1.	Lift pump suction line.

6.2.	Lift pump feed line.

6.3.	Fuel filter outlet line.

6.4.	Fuel filter drain line.

6.5.	Fuel return line.

7. Inspect each of the pipes and replace any rusted pipes.
8. Clean the inside of the fuel filter housing and dry it with compressed air.
9. Dry the inside of each line with low pressure air.
10. Remove FUEL SOL fuse from fuse panel.
11. Install a new fuel filter element.
12. Install the fuel sender and fuel tank (add clean diesel fuel to ¼ full).
13. Reconnect the following lines.

13.1.

Lift pump suction (both ends) lines.

13.2.

Lift pump feed (both ends) lines.

13.3.

Fuel filter drain line.

13.4.

Fuel return (at injection pump) line.

14. Connect the fuel filter outlet and the fuel return line at the fuel sender to hoses that flow to metal containers.
15. Connect the batteries, and use scan tool to command lift pump ON. Operate lift pump until clean fuel flows from the fuel filter outlet into a metal container.
16. Connect the hose from the fuel filter outlet to the injection pump inlet.
17. Open each injection line at its nozzle end and crank the engine until clean fuel flows from it.

17.1.

Use two wrenches when loosening the injection line fittings.

17.2.

Allow a maximum of 15 seconds cranking time, followed by 1 minute of cranking motor cooling time.

18. Tighten each injection line fitting at its nozzle. Use two wrenches when tightening the injection line fittings.
19. Install FUEL SOL fuse in fuse panel.
20. Start and run the engine for 1 minutes while fuel flows from the fuel return line into a metal container.
21. Stop the engine.
22. Connect the fuel return hose to the fuel sender.
23. Clean the engine of fuel spillage.
24. Fill the fuel tank and add a biocide, if needed.

1. Drain the fuel tank.
2. Fill the fuel tank.
3. Remove FUEL SOL fuse from fuse panel.
4. Remove the fuel filter outlet and connect it to a hose that flows to a metal container.
5. Use a scan tool and command lift pump ON until clean fuel flows from the fuel filter outlet into a metal container.
6. Connect the hose from the fuel filter outlet to the injection pump inlet.
7. Install FUEL SOL fuse in fuse panel.
8. Atempt to start and run the engine for 15 minutes (If engine does not start, purge the injection system).
9. Stop the engine.
10. Clean the engine of fuel spillage.
11. Clear engine DTC(s).