STANDARD PROCEDURE
FUEL CONTAMINATION
If a diesel engine's fuel supply has been contaminated (with gasoline, water, etc.), the following procedure must be followed:
1. Remove all fuel from the fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE-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 and clean fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL)
3. Install the fuel tank. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - INSTALLATION)
4. Fill fuel tank with fresh diesel fuel.
5. Drain and remove the fuel filter. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEPARATOR - REMOVAL)
6. Install a new fuel filter. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEPARATOR - INSTALLATION)
7. Check the engine control module for any diagnostic trouble codes (DTCs). Record and clear any DTCs that are present.
8. Start and run the engine. Run the engine for up to 15 minutes to allow time for any DTCs to reset and shut off the engine.
9. Check the engine control module for any diagnostic trouble codes (DTCs). Record any DTCs that are present. Refer to the appropriate engine electrical diagnostics to diagnose any DTCs that were set.
CAUTION: With the high pressure fuel system in this vehicle, any residual contaminated fuel will be removed very quickly. Shut off the engine immediately if signs of engine damage are noted.
The engine should then be evaluated to determine if the contaminated fuel has caused any damage to the fuel system and/or engine. Indicators that the fuel system has been damaged include the following:
- Unstable fuel rail pressure. This can manifest itself as instability of idle speeds, excessive undershoot/overshoot at engine start-up, or excessive undershoot/overshoot when the engine operating conditions change. A typical engine response to a large rail pressure undershoot would be a decrease in engine speed or engine stall.
- Excessive noise from the engine. This could indicate poor rail pressure control or the inability of the injection system to inject the proper amount of fuel.
- Excessive smoke (black or white). This could indicate the inability of the fuel system to inject the proper amount of fuel.
NOTE: If any of these conditions are exhibited after cleaning the fuel system, proceed to the appropriate engine electrical diagnostic information. Repair the fuel system and/or engine as necessary.
BLEEDING AIR FROM FUEL SYSTEM
WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing.
1. Turn the ignition off.
2. Remove engine cover.
3. Connect a hose to the fuel filter air bleed port and insert the remaining end into a approved and appropriately marked container.
4. Turn the air bleed counterclockwise to open the air bleed.
CAUTION: Turning the ignition to the on position will engage the in tank fuel pump. Be sure that the bleed hose and the fuel capture container is secure.
5. Turn the ignition to the on position and observe the container until fuel flows free of bubbles.
6. Turn the ignition off.
7. Tighten the bleed valve on the fuel filter.
8. Remove the bleed hose and container.
9. Install engine cover. (Refer to 9 - ENGINE - INSTALLATION)
DRAINING FUEL TANK - DIESEL
A one-way check valve is located within the fuel fill fitting on the fuel tank. Because of this valve, the tank cannot be drained the conventional way through the fuel fill opening.
To drain the tank, the fuel pump module must be removed.
1. Remove fuel tank (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TANK - REMOVAL).
2. Remove fuel pump module (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP MODULE - REMOVAL).
3. After fuel pump module has been removed, drain fuel into an approved diesel fuel oil draining station.