Orlando

Fuel System Cleaning

Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
2. Remove the fuel tank. Refer to Fuel Tank 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.

Warning: Wear safety glasses when using compressed air in order to prevent eye injury.

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 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. Clean the inside of the fuel filter housing.
9. Dry the fuel filter housing with compressed air.
10. Dry the inside of each line with low pressure air.
11. Install a new fuel filter. Refer to Fuel Filter Replacement .
12. Install the fuel tank. Refer to Fuel Tank Replacement .
13. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
14. 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)

15. Connect the fuel filter drain to a line that flows into a clean metal container.
16. Connect the batteries.
17. Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into a metal container.
18. Install a hose on the fuel return line, and insert other end into a 7.6 litre (2 gallon) metal container.
19. Crank the engine for 30 second time intervals, with 1 minute cool-down periods. Continue until 3.8 litres (1 gallon) of fuel has passed into the container.
20. Connect the fuel return line.
21. Start and run the engine.
22. Stop the engine.
23. Clean any fuel spillage from the engine.
24. Fill the fuel tank and add a biocide, if needed.

1. Drain the fuel tank.
2. Fill the fuel tank to 1/4 full.
3. Unplug the crankshaft position (CKP) sensor.
4. Disconnect the fuel return line near the cylinder head.
5. Install a hose on the fuel return line, and insert the other end into a 7.6 litre (2 gallon) metal container.
6. Crank the engine for 15 second time intervals, with 1 minute cool-down periods. Continue until 3.8 litres (1 gallon) of fuel has passed into the container.
7. Reconnect the fuel return line.
8. Plug in the CKP sensor.
9. Attempt to start and run the engine for 15 minutes. If the engine does not start, turn on/off ignition ten times, that the fuel pump module convey fuel to the fuel injection pump.
10. Stop the engine.
11. Clean any fuel spillage from the engine.
12. Clear the engine of any diagnostic trouble codes (DTCs).

Note: 

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the fuel tank. Refer to Fuel Tank Replacement .
4. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump.
5. Inspect the fuel pump inlet for dirt and swarf. Replace the fuel pump if you find dirt or swarf in the fuel pump inlet.
6. Locate a stand or fixture suitable to support the weight of the fuel tank and water.
7. Turn the in-frame rail fuel tank over so that the modular reservoir assembly opening is facing down.
8. Install side mounted fuel tanks upright and horizontal on stand of fixture and remove the drain plug and set aside for re-installation.

Note: 

•	When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state, and federal laws and regulations.

•	Do not drill any access or drain holes in the fuel tank.

9. Using a high pressure water spray-wand, spray all interior surfaces with clean/non-contaminated water. Be sure to spray all interior tank surfaces including for and aft sections of tank behind baffles, while allowing water to drain out the modular reservoir assembly opening or drain hole. Perform each wash cycle for a minimum of 30 seconds using a minimum of 4 litres (1 gallon) of clean/non-contaminated water.
10. Using a high pressure wand, dry all interior tank surfaces. Tank should be tipped accordingly to facilitate removal of water. Assure pressurised air does not contain any contaminants.
11. Repeat steps 10 and 11 for a total of 3 wash/dry cycles.
12. Hand dry tank surfaces with a white towel to confirm dryness and cleanliness.

Use a non-metallic extension to push the towel beyond tank baffles.