Perform the following procedures for removal and installation of the fuel filter.
Fuel Filter Removal
Remove the fuel filter as follows:
To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open flames, sparks, and electrical resistance heating elements. Do not smoke when refueling.
Disconnect the batteries.
Open the fuel fill cap to release pressure in the fuel system. Replace and tighten the cap.
Using a 36-mm socket wrench, unscrew the cap on the fuel filter. Pull both the cap and the filter element a short distance out of the filter housing. See Figure
. Allow the fuel to drain off the filter into the housing.
1. Mounting Bracket
7. Seal Ring
2. Fuel Filter Housing
8. Banjo Fitting
3. Filter Element
9. Fuel Delivery Line
10. Fuel Return Line
5. Fuel Filter Cap
11. Fuel Drain Line
6. Banjo Bolt
Removing the Filter Housing
To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or goggles.
Disconnect the fuel return line from the filter housing. Mark both sides of the connection with a paint pen. Discard the seal rings.
Catch any fuel that runs out of the filter housing or fuel return line.
Remove the fuel delivery and drain lines from the filter housing. Mark both sides of each connection with paint pens. Discard the seal rings.
In a suitable container, catch any fuel that runs out of the filter housing or fuel lines.
Remove the bolts attaching the filter housing to the mounting bracket.
Remove the filter housing from the engine.
Clean the fuel filter cap. Discard the filter element.
Fuel Filter Installation
Install the fuel filter as follows:
Install the filter housing on the mounting bracket. Tighten the mounting bolts 25 Nm (18 lbft).
Install the drain and delivery lines, as removed. Install new seal rings on the banjo fittings. Tighten the banjo bolts 40-50 Nm (30-37 lbft).
Install the return line, as removed. Install new seal rings on the banjo fitting. Tighten the banjo bolt 40-50 Nm (30-37 lbft).
Install a new filter element in the main filter cap. Inspect the O-ring and replace it if necessary. Screw the cap onto the filter housing. Tighten the cap 25 Nm (18 lbft).
Connect the batteries.
Prime the fuel system.
Make sure that all high-pressure lines have been tightened to 30 Nm (22 lbft) and all banjo bolts to 40-50 Nm (30-37 lbft).
Correct torque on the high-pressure lines is critical. Incorrect torques could result in leaks or lack of power due to restricted fuel flow.
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Always start and operate an engine in a well ventilated area.
If operating an engine in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system or emission control system.
Crank the engine for 30 seconds at a time, but no longer. Before cranking the engine again, wait at least two minutes. The engine should start within four 30-second attempts.
DDC does not recommend opening the high-pressure lines and bleeding the air from the fuel system while cranking.
With the engine running, check the fuel filter for leaks. Shut down the engine.