Questionjust changed the fuel filter in my truck and now it won't start can you help?
AnswerU haft to bleed out the air that u introduced to the system.
FUEL FILTER/WATER SEPARATOR
Refer to maintenance schedules in Group 0 in this manual for recommended fuel filter replacement intervals.
The fuel filter/water separator assembly is located on left/rear side of engine above starter motor Fuel Filter/Water Separator/Drain Hose Location The assembly contains the fuel filter cartridge, Water-In-Fuel (WIF) sensor, and fuel heater.
REMOVAL
Draining water from filter canister:
The canister drain valve Drain Valve at Fuel Filter/Water Separator serves two purposes. One is to partially drain filter canister of excess water. The other is to completely drain canister for filter, heater or water-in-fuel sensor replacement.
The filter should be drained whenever water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check)
A drain hose is located at bottom of drain valve Fuel Filter/Water Separator Components Place drain pan under drain hose.
With engine not running, rotate drain valve handle forward to OPEN (DRAIN) position Drain Valve at Fuel Filter/Water Separator Hold drain valve open until all water and contaminants have been removed and clean fuel exits drain hose.
If fuel filter, fuel heater or Water-In-Fuel (WIF) sensor is being replaced, drain canister completely. Dispose of mixture in drain pan according to applicable regulations.
After draining operation, rotate valve handle rearward to CLOSE position Drain Valve at Fuel Filter/Water Separator If fuel filter, fuel heater or WIF sensor is being replaced, proceed to next step.
Remove drain hose at drain valve Fuel Filter/Water Separator/Drain Hose Location
Disconnect Water-In-Fuel (WIF) sensor electrical connector at sensor. The WIF sensor is located at side of filter canister Fuel Filter/Water Separator Components
Loosen filter canister nut at top of header Fuel Filter/Water Separator Components while lowering canister assembly from header.
Remove and discard seals and center o-rings Fuel Filter/Water Separator Components
Remove filter element (cartridge) from canister.
Remove WIF sensor and its o-ring seal from canister Fuel Filter/Water Separator Components
Inspect WIF sensor probes Fuel Filter/Water Separator Components Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up.
Fuel Heater: The fuel heater is located inside fuel filter housing (header) Fuel Filter/Water Separator/Drain Hose Location , Fuel Filter/Water Separator Components or Fuel Heater Mounting Screws (Bottom View) The heater mounting plate, heating element, temperature sensor and wiring harness are serviced as one assembly.
Disconnect heater pigtail harness electrical connector Fuel Heater Mounting Screws (Bottom View) from main engine wiring harness near upper/rear of filter.
The plastic electrical connector Fuel Heater Mounting Screws (Bottom View) at end of 2 - wire pigtail harness will have to be removed from wiring harness before attempting to pass harness through filter header.
Note locations (colors) of wires in connector before removing connector.
Remove clip Fuel Filter/Water Separator Components retaining wires to connector.
Remove wires from connector.
Remove 3 fuel heater mounting screws Fuel Filter/Water Separator Components or Fuel Heater Mounting Screws (Bottom View)
Press down on heater sealing grommet Fuel Filter/Water Separator Components to remove heater from filter canister header.
Pass wire harness through hole in filter header while removing heater from header.
INSTALLATION
Clean inside of canister and canister header.
Fuel Heater:
Lift fuel heater assembly into filter header while passing wire harness upward through hole in header. Heater sealing grommet should protrude at top of filter header.
Install 3 fuel heater mounting screws Fuel Heater Mounting Screws (Bottom View) or Fuel Filter/Water Separator Components and tighten to 2 - 3 N·m (15 - 20 in. lbs.) torque.
Install 2 wires into electrical connector and install connector clip.
Connect heater pigtail harness electrical connector Fuel Heater Mounting Screws (Bottom View) to main engine wiring harness.
Install new o-ring seal to WIF sensor.
Install WIF sensor to canister. Tighten to 2 - 3 N·m (15 - 20 in. lbs.) torque.
If drain valve assembly is being replaced, tighten mounting screws to 3 - 5 N·m (30 - 40 in. lbs.) torque.
Install new o-rings.
Install new seal between canister and canister header.
If filter canister is not filled with clean diesel fuel before installation, manual air bleeding of fuel system may be necessary (temporary rough engine running may occur) If necessary, refer to Air Bleed Procedures.
Load filter into canister.
Fill filter canister with clean diesel fuel.
Apply a light film of clean diesel oil to all seals.
Position canister assembly to canister header. Note locating tabs on canister should align into notch on canister header Fuel Filter/Water Separator Components
Install canister nut and tighten to 14 N·m (10 ft. lbs.) torque.
Connect electrical connector to WIF sensor.
Connect drain hose to bottom of drain valve.
Start engine and check for leaks.
AIR BLEED PROCEDURE
A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Primary air bleeding is accomplished using the electric fuel transfer (lift) pump. If the vehicle has been allowed to run completely out of fuel, the fuel injectors must also be bled as the fuel injection pump is not self-bleeding (priming)
Servicing or replacing components on the fuel return side will not require air bleeding.
WARNING: DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE.
Loosen, but do not remove, banjo bolt holding low-pressure fuel supply line to side of fuel injection pump Fuel Supply Line Banjo Bolt Place a shop towel around banjo fitting to catch excess fuel
The fuel transfer (lift) pump is self-priming: When the key is first turned on (without cranking engine), the pump operates for approximately 2 seconds and then shuts off. The pump will also operate for up to 25 seconds after the starter is engaged, and then disengaged and the engine is not running. The pump shuts off immediately if the key is on and the engine stops running.
Turn key to CRANK position and quickly release key to ON position before engine starts. This will operate fuel transfer pump for approximately 25 seconds.
If fuel is not present at fuel supply line after 25 seconds, turn key OFF. Repeat previous step until fuel is exiting at fuel supply line.
Tighten banjo bolt at fuel supply line to 24 N·m (18 ft. lbs.) torque. Primary air bleeding is now completed.
Attempt to start engine. If engine will not start, proceed to following steps. If engine does start, it may run erratically and be very noisy for a few minutes. This is a normal condition.
Continue to next step if:
The vehicle fuel tank has been allowed to run empty
The fuel injection pump has been replaced
High-pressure fuel lines have been replaced
Vehicle has not been operated after an extended period
CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals.
Perform previous air bleeding procedure steps using fuel transfer pump. Be sure fuel is present at fuel supply line Fuel Supply Line Banjo Bolt before proceeding.
Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold
WARNING: THE FUEL INJECTION PUMP SUPPLIES EXTREMELY HIGH FUEL PRESSURE TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH-PRESSURE LINES. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE THE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING AND AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE FUEL LINES.
WARNING: ENGINE MAY START WHILE CRANKING STARTER MOTOR.
Engine may start, may run erratically and be very noisy for a few minutes. This is a normal condition.
Thoroughly clean area around injector fittings where they join injector connector tubes.
Bleed air by loosening high-pressure fuel line fittings Bleeding High-Pressure Fuel Lines at Injectors at cylinders number 3, 4 and 5
Continue bleeding injectors until engine runs smoothly. It may take a few minutes for engine to run smooth.
Tighten fuel line(s) at injector(s) to 38 N·m (28 ft. lbs.) torque.
