Savana 3500 V8-6.6L DSL Turbo VIN 6 (2007)
Fuel System Components Check List for Warranty
This labor operation is on 100% return to the Warranty Parts Center (WPC). DO NOT return any parts associated with J7811 to core. You must return
the pump, two rails and injectors when you receive the WPC request. All documentation as outlined above must be returned with the parts. For example:
RO with tech notes, snap shot and the graph of the pump.
Disclaimer
Correction
Correction
Caution
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you
relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In
order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may
leak out. Place the towel in an approved container when the disconnection is complete.
Important
Make sure you clock in and record the actual repair order clock time when completing this repair. A copy of the repair order and a print out of
the Engine Data 1 snapshot along with the fuel rail pressure graph may be required. Failure to provide copies of this information may cause
your warranty claim to be rejected.
Start by diagnosing the fuel system components by referring to Fuel System Diagnosis in SI.
If the vehicle starts and runs, verify that there are no fuel pump inlet restrictions on the supply side by inspecting for kinked fuel lines or a clogged fuel
filter. If the vehicle does not exhibit any fuel supply restrictions or the engine does not start, proceed with the following diagnosis:
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If the past repair order history shows the fuel injection pump was replaced, inspect the left fuel rail for debris and/or fuel contamination. It will be
necessary to remove the fuel pressure relief valve to visually inspect inside the fuel rail. Refer to Fuel Pressure Relief Valve Replacement in SI.
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If particle debris is found in the left fuel rail, perform Steps 12-19.
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If no debris is found in the left fuel rail, install the fuel pressure relief valve and tighten. Perform the fuel injector return flow test by referring
to Fuel Return System Diagnosis in SI.
Tighten
Tighten the fuel pressure relief valve to 100 Nm (74 lb ft).
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If the vehicle will not start and/or there is evidence of a leak coming from the fuel injection pump, inspect for a missing or damaged cup plug on
the fuel injection pump. If a damaged cup plug is found, perform Steps 11-19.
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If the fuel injection pump has not been previously replaced and there is no evidence that the cup plug is damaged, test the fuel injection pump for
excessive fuel pressure fluctuations by following Steps 1- 10 below.
