Fuel System - General Information - Diesel Filter Water Drain-Off

Published: 11-May-2011
Fuel System - General Information - Diesel Filter Water Drain-Off

General Procedures
WARNINGS:
The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent
fire and explosion.
Do not carry or operate cellular phones 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.
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.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention.
Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek
medical attention.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
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therefore essential that absolute cleanliness is observed when working with these components. Always install blanking
plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel
injection system.
1. Drain the fuel filter element.

Attach a suitable drain tube to the fuel filter water
drain off port.
Loosen the water drain off port one complete turn
and allow the fuel to drain into a container.
Tighten the water drain off port.
Remove the drain tube.
Remove the container.
2. Bleed the fuel system.

For additional information, refer to: Low-Pressure Fuel System
Bleeding (310-00, General Procedures).
Fuel System - General Information - Fuel Tank Draining
General Procedures
1. Remove battery cover.
2. Disconnect both leads from battery, earth lead first.
WARNING: Fuel vapour is highly flammable and in contained spaces is also explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR POWDER close at hand when handling or draining fuel.
3. Using a fuel recovery appliance, drain the fuel from the tank into a
sealed container. Follow the manufacturers instructions for the
connection and safe use of the appliance.
4. Remove filler cap and insert hose into filler neck.
5. Connect bowser earth line. Drain fuel.
6. Connect battery leads.
7. Fit battery cover.
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Fuel System - General Information - Low-Pressure Fuel System Bleeding
General Procedures
Special Tool(s)
Hand pressure pump
310-110
WARNINGS:
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may
result in personal injury.
personal injury.
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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.
medical attention.
CAUTIONS:
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. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system
and may result in later malfunction.
1. Disconnect the fuel injection pump supply line.

For additional information, refer to: Quick Release
Coupling (310-00, General Procedures).
Position an absorbent cloth to collect any fluid
spillage.
2. Install the special tool.

Operate the hand pressure pump special tool
until fuel starts to flow through the clear plastic
pipe and the special tool becomes firm.
3. Remove the special tool.
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4. Connect the fuel injection pump supply line.
For additional information, refer to: Quick Release Coupling (310-00,
General Procedures).
Remove the absorbent cloth.
Fuel System - General Information - Quick Release Coupling
General Procedures
WARNINGS:
After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may
result in personal injury.
personal injury.
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.
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medical attention.
CAUTIONS:
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. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible.
Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system
and may result in later malfunction.
1. Disconnect the fuel line quick release coupling.

Push the fuel line quick release buttons and pull
the 2 halves of the fuel line to disconnect.
2. CAUTION: Make sure the fuel line quick release

coupling clicks into place when connecting the fuel line.
To make sure that the quick release coupling is fully
seated pull on the 2 halves of the fuel line.
Connect the fuel line quick release coupling.

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Fuel System - General Information - Diesel Filter Water Drain-Off

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Published: 11-May-2011

Fuel System - General Information - Diesel Filter Water Drain-Off

1. Drain the fuel filter element.

2. Bleed the fuel system.

1. Remove battery cover.

2. Disconnect both leads from battery, earth lead first.

4. Remove filler cap and insert hose into filler neck.

5. Connect bowser earth line. Drain fuel.

6. Connect battery leads.

7. Fit battery cover.

1. Disconnect the fuel injection pump supply line.

2. Install the special tool.

1. Disconnect the fuel line quick release coupling.

2. CAUTION: Make sure the fuel line quick release

Connect the fuel line quick release coupling.

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