Diesel Fuel System Contamination Repair/Flushing

WARNING: This page is about a different variant/trim than selected.

Flushing

NOTE: This procedure is to be used when metal debris and/or fuel system contamination is present.

NOTE: This procedure is for flushing the low pressure fuel system lines from the fuel tank, through the HP (high pressure) fuel injection pump to remove all contaminates before installing new fuel system components.

NOTE: Leave the HP fuel injection pump, fuel lines, fuel rail and injectors in place until the flushing procedure is completed to prevent contamination of replacement components.

NOTE: All remaining low pressure fuel lines can be reused if no physical damage is present.

1.

Remove and flush the fuel pump. Refer to: Fuel Pump and Sender Unit .

2.

NOTE: Dispose of contaminated fuel in accordance with local laws and regulations.

Flush the fuel tank out.

3.

NOTE: Do not install the fuel tank at this time.

Install the fuel pump. Refer to: Fuel Pump and Sender Unit .

4.

Flush all fuel lines from the fuel tank to the fuel filter.

5.

Install the fuel tank. Refer to: Fuel Tank .

6.

Replace the fuel filter element. Refer to: Fuel Filter Element .

7.

Add 5 gallons of fresh, clean, good quality diesel fuel.

8.

Flush the fuel lines (supply and return) to the engine. Disconnect the return line quick release coupling and place in a suitable container. Refer to: Quick Release Coupling .

9.

Using the Scan Tool, Command the Fuel Pump (FP-MODE) PID on for at least 1 minute. Ensure that no further contamination is present.

10.

Using the Rotunda fuel pressure test kit (310-193) fuel line return plug, plug off the return line fitting.

11.

Disconnect the supply line quick release coupling and place into a suitable container. Refer to: Quick Release Coupling .

12.

NOTE: Depending on the contamination present, more fuel may need to be added to the fuel tank to thoroughly flush the lines of all contamination.

Using the Scan Tool, Command the FP-MODE PID on again for at least 1 minute. Ensure that no further contamination is present.

13.

After the flush is completed, replace the following HP fuel system components:
- Fuel injection pump
- Fuel rail supply tube
- Fuel injector supply tubes
- Fuel injector fuel return line
- Fuel rail
- Fuel injectors