Express 3/4 Ton Van V8-6.5L DSL Turbo VIN F (1999)
Fuel: Service and Repair
Cleaning Water From the Fuel System
1. Disconnect the batteries.
2. Drain the fuel tank.
3. Remove the fuel tank. Refer to Fuel Tank Replacement (Passenger/Cargo Van), or Fuel Tank Replacement (Commercial/ RV Cutaway Van).
4. Remove the fuel sender unit. (Refer to Fuel Sender Assembly Replacement).
5. Inspect the fuel tank and the fuel sender for rust, fungi or bacteria.
6. Clean the inside of the fuel tank and the fuel sender with hot water.
7. Dry the fuel tank and the fuel sender with compressed air.
8. Disconnect the ends of the following lines.
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The lift pump suction line
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The lift pump feed line
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The fuel filter outlet line
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The fuel return line
9. Inspect each of the pipes and replace any rusted pipes.
10. Clean the inside of the fuel filter housing.
11. Dry the inside of the fuel filter housing with compressed air.
12. Dry the inside of each line with low pressure air.
13. Remove the ENG 1 fuse from the fuse panel.
14. Install a new fuel filter element.
15. Install the fuel sender and the fuel tank (add clean diesel fuel to 1/4 full).
16. Reconnect the following lines.
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The lift pump suction (both ends) lines
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The lift pump feed (both ends) lines
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The fuel return (at injection pump) line
17. Connect the fuel filter outlet and the fuel return line at the fuel sender to the hoses that flow to the metal containers.
18. Connect the batteries.
19. Use the scan tool in order to command the lift pump ON.
20. Operate the lift pump until the clean fuel flows from the fuel filter outlet into a metal container.
21. Connect the hose from the fuel filter outlet to the injection pump inlet.
22. Open each injection line at each nozzle end.
23. Crank the engine until the clean fuel flows from it.
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Use two wrenches when loosening the injection line fittings.
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Allow a maximum of 15 seconds cranking time, followed by 1 minute of cranking motor cooling time.
24. Use two wrenches in order to tighten each injection line fitting at its nozzle.
25. Install the ENG 1 fuse in the fuse panel.
26. Start the engine.
27. Allow the engine to run for 1 minute while the fuel flows from the fuel return line into a metal container.
28. Stop the engine.
29. Connect the fuel return hose to the fuel sender.
30. Clean the engine of fuel spillage.
31. Fill the fuel tank and add a biocide, if needed.
