Low-Pressure Fuel System Bleeding
Low-Pressure Fuel System Bleeding
WARNING:
- Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to follow this instruction may result in personal injury.
- Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
- After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.
- If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.
- If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.
- Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
- 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 fit blanking plugs to any open orifices or lines.
- This procedure must be carried out before the engine is attempted to be started, following removal or replacement of any low pressure fuel system component. Failure to follow this instruction will result in damage to the fuel injection pump.
- The engine must not be cranked using the starter motor for more than 30 seconds. The starter motor must be allowed to cool for at least 5 minutes after cranking for 30 seconds. Failure to follow these instructions will result in damage to the starter motor.
NOTE: This procedure is necessary if any low-pressure fuel system components are removed or replaced. These include the fuel filter, fuel lines, fuel tank or fuel cooler.
1. Disconnect the fuel filter to fuel pump supply line from the fuel filter.
CAUTION: The tube used to bleed the low pressure fuel system must be absolutely clean. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
2. Connect a suitable clean, clear tube to the fuel pump supply outlet.
3. Place a suitable container under the tube to catch any escaping fuel.
4. Turn the ignition switch to the ON position for 10 seconds. The fuel pump in the fuel tank will be audible.
5. Turn the ignition switch to the OFF position.
6. Repeat steps 2 and 3 until air-free fuel escapes from the tube.
7. Disconnect and discard the tube from the fuel filter outlet line.
8. Connect the fuel filter to fuel pump supply line to the fuel filter.
CAUTION: If any high pressure fuel system components have been removed or replaced, the high pressure fuel system bleeding procedure must be carried out before the engine is started. Failure to follow this instruction may result in damage to the fuel injection pump.
9. If necessary, bleed the high pressure fuel system.
10. Start the engine and allow to idle.