Section 2
Section 2
Fuel SystemFuel System
Introduction.Introduction. Fuel is Fuel is drawn from drawn from the fuel tthe fuel tankank
through a fuel / water separator and fuel filter bythrough a fuel / water separator and fuel filter by
the fuel pump. the fuel pump. From here, the fuel From here, the fuel is sent to tis sent to thehe
fuel rail and fuel rail and onto the fuel onto the fuel injectors. injectors. Unused fuel isUnused fuel is
returned into the fuel tank.returned into the fuel tank.
Death or serious injury couldDeath or serious injury could
result from higresult from high pressure fuel sprh pressure fuel spray. ay. The fuelThe fuel
pump, high-pressure fuel lines, and fuel railpump, high-pressure fuel lines, and fuel rail
contain very contain very high-pressure high-pressure fuel. fuel. Do not Do not loosenloosen
any fittings while thany fittings while the engine is rune engine is running. ning. WaitWait
at least 10 minutes after shutting down theat least 10 minutes after shutting down the
engine before loosening any fittings in theengine before loosening any fittings in the
high-pressure fuel system to allow pressure tohigh-pressure fuel system to allow pressure to
decrease to a lower level.decrease to a lower level.
Major Components.Major Components. The fuel The fuel system csystem consists ofonsists of
a fuel tank, fuel / water separator, fuel filter, fuela fuel tank, fuel / water separator, fuel filter, fuel
injection pump, fuel rail, fuel injectors and fuelinjection pump, fuel rail, fuel injectors and fuel
lines.lines.
Adding FuelAdding Fuel (Illustration 2-3)(Illustration 2-3).. When When addingadding
diesel fuel to the fuel tank, make sure the fueldiesel fuel to the fuel tank, make sure the fuel
strainer is in the filler neck and free of debris.strainer is in the filler neck and free of debris.
Adding fuel Adding fuel with the strainer with the strainer removed could leadremoved could lead
to debris entering the fuel tank, resulting in poorto debris entering the fuel tank, resulting in poor
engine performance.engine performance.
Changing The Fuel FiltersChanging The Fuel Filters (Illustrations 2-1 and(Illustrations 2-1 and
2-2)2-2).. With the engine shut down, perform theWith the engine shut down, perform the
following procedures to replace the fuel / waterfollowing procedures to replace the fuel / water
separator and fuel filterseparator and fuel filter. . They should They should be replacedbe replaced
periodically or more often if conditions warrantperiodically or more often if conditions warrant
( f t th( f t th P ti M i tP ti M i t h t i thh t i th
1.1. ParPark the tk the trucruck on a hak on a hard, lrd, leveevel surl surfacface, ape, applyply
the parking brake, block the wheels in boththe parking brake, block the wheels in both
directions to prevent movement of the truckdirections to prevent movement of the truck
and Lock Out & Tag Out the truck.and Lock Out & Tag Out the truck.
2.2. DiscoDisconnect nnect the the wire wire harnesharness fs from rom the the waterwater-in--in-
fuel sensor located on the bottom of the fuel /fuel sensor located on the bottom of the fuel /
water water separatorseparator..
3.3. ProProvidvide a suite a suitable cable contontainainer to caer to catch dtch drairainedned
fuel and use the drain valve to drain fuel out offuel and use the drain valve to drain fuel out of
the fuel / water separator for approximatelythe fuel / water separator for approximately
5 seconds (refer to procedure 2. of5 seconds (refer to procedure 2. of DrainingDraining
The Fuel / Water SeparatorThe Fuel / Water Separatorin this section).in this section).
This will eliminate fuel from running over theThis will eliminate fuel from running over the
top of the filter upon removal.top of the filter upon removal.
4.4. RemRemove thove the fuel fe fuel filtilter and fer and fuel / wauel / water ster sepaepara-ra-
tor from the adapters with a strap wrench.tor from the adapters with a strap wrench.
5.5. CleClean tan the arhe area area arounound the d the filfilter hter headeads.s.
NOTE:NOTE: Do not fill Do not fill the fuel / the fuel / water separator or water separator or fuelfuel
filter with fuel before installation as this will allowfilter with fuel before installation as this will allow
unfiltered fuel to enter the system and may causeunfiltered fuel to enter the system and may cause
damage to fuel system components.damage to fuel system components.
6.6. InstaInstall the ll the fuel / fuel / water water separaseparator antor and fuel d fuel filtefilterr..
Tighten them 1/2 turn after the seals contactTighten them 1/2 turn after the seals contact
the adapters.the adapters.
7.7. InstaInstall tll the wahe water–iter–in–fuel n–fuel sensosensor intr into tho the fuee fuel /l /
water water separatorseparator..
8.8. PriPrime tme the fhe fuel uel syssystem tem (ref(refer ter too Priming ThePriming The
Fuel SystemFuel Systemin this section).in this section).
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