Fuel System Cleaning

FUEL SYSTEM CLEANING

Fungi and other microorganisms can survive and multiply in diesel fuel if water is present. The fungi can be present in any part of the fuel handling system.

These fungi grow into long strings and will form into large globules. The growths appear slimy and are usually black, green, or brown. The fungi may grow anywhere in the fuel but are most plentiful where diesel fuel and water meet. As the fuel is agitated, when service station tanks are being filled, fungi are distributed throughout the tank and may be pumped into a vehicle.

Fungi use the fuel as their main energy supply and need only trace amounts of water and minerals. As they grow and multiply, they change fuel into water, sludge, acids, and products of metabolism. The most common symptom is fuel filter plugging; however, various metal components including the fuel sending unit, pipes, fuel injectors, and injection pump can corrode.

CAUTION: Avoid physical contact with the biocides in order to avoid personal injury.

If fungi have caused fuel system contamination, use a diesel fuel biocide to sterilize the fuel system. Do not exceed the dosage recommended on the label.

Discontinue the use of a biocide when towing a trailer. It is permissible to have biocide in the fuel when starting to tow, but do not add any biocide while towing.

Steam cleaning may be necessary if most of the fungus growth cannot be removed with biocides.

The presence of water or gasoline in diesel fuel may also cause injection pump and nozzle damage.

This procedure checks for the presence of water and gasoline in diesel fuel that may cause injection pump and nozzle damage.

Remove and inspect the fuel filter element.
- If water, gasoline or fungi/bacteria are not present, end the inspection.
- If water or fungi/bacteria are present, proceed to Cleaning Water from the Fuel System.
- If gasoline is present, proceed to Cleaning Gasoline from the Fuel System.

Cleaning Water from the Fuel System
1. Disconnect the negative battery.
2. Remove the sending unit.
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.
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 transfer pump pressure line and suction line (if applicable)
- 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. Replace any rusted pipes.
9. Clean the inside of the fuel filter housing.
10. Dry the fuel filter housing with compressed air.
11. Dry the inside of each line with low pressure air.
12. Remove the ignition 1 relay from the underhood relay center.
13. Install a new fuel filter.
14. Install the sending unit.
15. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
16. 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)
17. Connect the fuel filter drain to a line that flows into a clean metal container.
18. Connect the batteries.
19. Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into a metal container.
20. Close the fuel filter drain and remove the bleeder hose.
21. Install a hose on the fuel return line near the glow plug relay, and insert other end into a 7.6 liters (2 gallon) metal container.
22. Crank the engine for 30 second time intervals, with 1 minute cool-down periods. Continue until 3.8 liters (1 gallon) of fuel has passed into the container.
23. Connect the fuel return line.
24. Install the ignition 1 relay in the underhood relay center.
25. Start and run the engine.
26. Stop the engine.
27. Clean any fuel spillage from the engine.
28. Fill the fuel tank and add a biocide, if needed.

Cleaning Gasoline from the Fuel System
1. Drain the fuel tank.
2. Fill the fuel tank to 1/4 full.
3. Remove the ignition 1 relay from the underhood relay center.
4. Loosen the fuel filter drain and connect the filter to a hose that flows into a metal container.
5. Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into the metal container.
6. Hand tighten the fuel filter drain and disconnect the hose.
7. Install a hose on the fuel return line near the glow plug relay, and insert the other end into a 7.6 liters (2 gallon) metal container.
8. Crank the engine for 30 second time intervals, with 1 minute cool-down periods. Continue until 3.8 liters (1 gallon) of fuel has passed into the container.
9. Reconnect the fuel return line.
10. Install the ignition 1 relay into the underhood relay center.
11. Attempt to start and run the engine for 15 minutes. If the engine does not start, operate the hand primer for 30 strokes, or until firm.
12. Stop the engine.
13. Clean any fuel spillage from the engine.
14. Clear the engine of any diagnostic trouble codes (DTCs).