| Removal and Installation Special Tool(s) | | Hand Pressure Pump with Adapter Kit 310-110 | General Equipment Materials Name Specification Engine Oil - 5W-30 WSS-M2C913-B Removal WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components. | | -
Remove the engine upper cover. | CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator. | | -
Protect the generator with lint-free material to prevent contamination. | | | -
Drain the fuel filter. - Connect a suitable length of fuel resistant tube to the fuel filter drain screw.
- Drain the fuel filter into a suitable container.
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Disconnect the fuel heater electrical connector. | | | -
Using the pneumatic vacuum gun. Clean the fuel filter fuel lines and surrounding area. For additional information, refer to: Fuel Injection Component Cleaning (303-04H Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures). | | | -
Detach the fuel filter fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install new blanking plugs to the open ends of the fuel filter fuel supply line and fuel filter union. | | | -
Detach the fuel filter to fuel pump fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Install new blanking plugs to the open ends of the fuel filter to fuel pump fuel supply line and fuel filter union. | | | -
Remove the fuel filter bracket. | CAUTION:Do not allow fuel from the fuel filter element to contaminate the adjacent components in the engine bay. Failure to follow this instruction, may result in premature failure of the contaminated components. CAUTION:Over a period of time, the O-ring seal between the fuel filter cover and the fuel filter bowl may become dry. Therefore a force greater than assembly force maybe required to separate the two components. When removing the fuel filter cover, a six sided socket must be used. Failure to follow this instruction, will result in damage to the fuel filter cover. | | -
Remove the fuel filter cover and fuel filter element. - Using a suitable six sided socket, rotate the fuel filter cover counterclockwise.
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Using a suitable lint-free material, cover the open fuel filter bowl. | | | -
Remove and discard the fuel filter element. | | | -
Install a new blanking plug to the fuel filter cover open connection. | | | -
Remove and discard the fuel filter cover O-ring seal. | Installation | | -
Install a new fuel filter cover O-ring seal. - Lubricate the fuel filter cover O-ring seal using clean engine oil.
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CAUTION:To prevent contamination, do not remove the fuel filter protective wrapping until the last possible moment. Install a new fuel filter element. - Remove and discard the fuel filter cover fuel filter element blanking plug.
- Remove the new fuel filter element protective wrapping.
- Assemble the fuel filter element to the fuel filter cover.
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Install the fuel filter cover and element to the fuel filter bowl. - Rotate the fuel filter cover clockwise until the fuel filter cover stop is engaged.
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Install fuel filter bracket. | | | -
Remove and discard the blanking plugs from the open ends of the fuel filter to fuel pump fuel supply line and fuel filter union. | | | -
Connect the fuel filter to fuel pump fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Remove and discard the blanking plugs from the open ends of the fuel filter fuel supply line and fuel filter union. | | | -
NOTE:Make sure the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Install the special tool between the fuel filter fuel supply line quick release coupling and the fuel filter union. | | | -
CAUTION:Do not allow excessive quantities of fuel to escape from the fuel filter bleed screw. Open the fuel filter fuel bleed screw. | | | -
Operate the hand pressure pump until fuel escapes from the fuel filter bleed screw. | | | -
Close the fuel filter bleed screw. | | | -
Operate the hand pressure pump until the fuel viewed through the clear fuel pump fuel supply line, is free of large quantities of air bubbles. | | | -
Remove the hand pressure pump. | | | -
Connect the fuel filter fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
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Remove the lint-free material protecting the generator. | | | -
CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again. Start the engine and allow to idle until it reaches normal operating temperature. | | | -
Install the engine upper cover. | | |
