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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. |
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Use a suitable container to catch any fuel that might spill. Clean up any spilled fuel immediately. |
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Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components. |
Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training.
After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel lines on a C7 engine and a C9 engine before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, "Fuel Injection Lines - Install".
The fuel system should be primed under the following conditions:
- The fuel tank is empty or the fuel tank has been partially drained.
- The engine has been in storage.
- The fuel filter has been replaced.
- The low pressure fuel lines have been disconnected.
Engines that are Equipped with a Fuel Priming Pump
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Do not loosen the fuel lines at the fuel manifold. The fittings may be damaged and/or a loss of priming pressure may occur when the fuel lines are loosened. |
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| Illustration 1 | g01525350 |
Secondary fuel filter and fuel priming pump (1) Secondary fuel filter (2) Fuel priming pump | |
- Check that the fuel supply valve (if equipped) is in the "ON" position.
- Open the fuel priming pump and operate the fuel priming pump until a strong pressure is felt. This procedure will require considerable strokes. Lock the fuel priming pump.
- Promptly start the engine. If the engine runs rough, continue to operate the engine at low idle. Do not raise the engine rpm above an idle, until the engine operates smoothly.
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Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. |
- If the engine does not start, open the fuel priming pump and repeat Steps 2 and 3 in order to start the engine.
Engines that are Not Equipped with a Fuel Priming Pump
If the engine is not equipped with a fuel priming pump, you can use the following procedures to prime the fuel system. These procedures will allow only filtered fuel to enter the fuel system.
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Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again. |
- Operate the starting motor. This will fill the fuel filter and the fuel lines with fuel.
- Once the engine starts, operate the engine at low idle. Do not raise the engine speed above an idle, until the engine operates smoothly.