Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

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

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. Refer to Fuel Sender Assembly Replacement .
7. Disconnect the fuel feed hose from the fuel 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. Refer to Fuel Filter Replacement .

1. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
2. Install the fuel tank. Refer to Fuel Tank Replacement .
3. Install the fuel feed pipes at the fuel lift pump.
4. Add clean diesel fuel into the tank until the tank is ¼ 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. Refer to Fuel Filter Replacement .
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.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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.

Engine Will Run or Start

1. Drain the fuel tank. Refer to Fuel Tank Draining .
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 .
2. Fill the fuel tank with diesel fuel.
3. Disconnect the engine shut-off 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 the hose 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 shut-off solenoid connector.
9. Start the engine.
10. Run the engine for 15 minutes.
11. Check for leaks.
12. Clear the engine DTCs.