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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Control System & Fuel System - 6.6L (LLY) - Introduction (2 Of 2)) >> Repair Instructions >> Fuel System Cleaning >> Cleaning Water from the Fuel System

Cleaning Water from the Fuel System

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the sending unit. Refer to Fuel Sender Assembly Replacement .
  3. Inspect the fuel tank and the fuel sender for rust, fungi or bacteria. If there is rust, replace the rusted components.
  4. Clean the inside of the fuel tank and the fuel sender with hot water.
  5. Use compressed air in order to dry the fuel tank and the fuel sender.
  6. Disconnect the ends of the following lines:
    • The fuel filter inlet line (both ends)
    • The transfer pump pressure line and suction line (if applicable)
    • The fuel filter outlet line (both ends)
    • The fuel filter drain
    • The fuel return line (both ends)
  7. Inspect each of the pipes and lines.
  8. Replace any rusted pipes.
  9. Clean the inside of the fuel filter housing.
  10. Dry the fuel filter housing with compressed air.
  11. Dry the inside of each line with low pressure air.
  12. Disconnect the crankshaft position (CKP) sensor. Refer to Crankshaft Position Sensor Replacement .
  13. Install a new fuel filter. Refer to Fuel Filter Replacement .
  14. Install the sending unit. Refer to Fuel Sender Assembly Replacement .
  15. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
  16. Reconnect the following lines:
    • The fuel filter inlet line
    • The fuel filter outlet line
    • The transfer pump pressure and suction (both ends) lines
    • The fuel return line (tank end)
  17. Connect the batteries.
  18. Install a hose on the fuel return line near the glow plug relay, and insert other end into a 7.6 liters (2 gallon) metal container.
  19. Turn ignition on with the engine OFF. Allow the fuel pump to run until the cycle ends or until 3.8 liters (1 gallon) of fuel has passed into the container.
  20. Turn the ignition OFF.
  21. Connect the fuel return line.
  22. Clean any fuel spillage from the engine.
  23. Reconnect the CKP sensor.
  24. Start and run the engine.
  25. Stop the engine.
  26. Check for oil leaks.
  27. Fill the fuel tank and add a biocide, if needed.
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