Def Fluid-Dirt-Metal-Or-Other Foreign Debris

If the fuel system has been contaminated with DEF Fluid, Dirt, Metal, or Other Foreign Objects, the following procedure must be followed:

1. Remove all fuel from the fuel tank. Use an appropriate fuel container. Refer to DRAINING FUEL TANK - DIESEL  . 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 the fuel tank. Refer to TANK, FUEL, REMOVAL AND INSTALLATION .
3. Ensure the swirl pot indentation below the in-tank electric fuel pump inlet is completely drained of any contaminated fuel and thoroughly clean the fuel tank.
4. Completely drain the low pressure fuel lines and flush with clean diesel fuel, then install a NEW  fuel filter.
5. Install the fuel tank, and fill with clean diesel fuel.
6. Remove the fuel quantity solenoid and inspect filter screen for DEF fluid crystals, excessive metal, or sand debris. Refer to VALVE, REMOVAL AND INSTALLATION . If debris is present skip down to step 10.
7. Disconnect the low pressure return line.
8. Connect a clean hose to the low pressure return line fitting and place the other end in a suitable clean container.
9. Turn the ignition ON, and collect the fuel escaping from the low pressure return into a clean container. Check the fuel sample for metal chips, dirt, or other foreign matter.
10. If any dirt, metal chips, or DEF fluid is present in the fuel sample, completely clean the low pressure side of the fuel injection system, then install NEW  fuel injectors, the high pressure fuel injection pump, and fuel rails along with NEW  fuel tubes.