Draining Sediment, Replacing the Fuel Filter. Bleeding Air from the Diesel Engine Fuel System

EVERY 80,000 KM

Gasoline is extremely flammable, so special precautions must be taken when working on any fuel system components. Do not smoke or bring open flames or unshielded portable lamps near the work area. Do not perform this work in garages equipped with natural gas-fired appliances (such as water heaters, dryers, etc.). The work area must be well ventilated. If gasoline gets on the skin, wash immediately with soap and water. When working on any part of the fuel system, wear safety glasses and keep a fire extinguisher within reach.

Replacing the Gasoline Engine Fuel Filter

Required tools:
a) Jack and stands.
b) Two small clamps for pinching off the fuel hoses.
c) Container for collecting spilled gasoline.
Also required:
d) Fuel filter for the appropriate engine.
e) Two clamps for securing the fuel lines.

PROCEDURE
1. Relieve the pressure in the fuel system.
2. The fuel filter is located on the left side member under the driver's seat. It is accessible from below only.
3. Raise the vehicle and support it on stands. Remove the engine undershield. Refer to Engine Undershield Removal and Installation.
4. Remove the trim cover in the area of the filter.

5. Pinch off the fuel hoses before and after the filter with hose clamps. Refer to the accompanying illustration.
6. Loosen clamps (1) and (3) and disconnect the fuel hoses from the filter.
7. Loosen the filter bracket bolt (2) and remove the filter.

* Collect the spilled fuel in a container and dispose of it in accordance with environmental regulations. Do not use an open flame. Keep a fire extinguisher ready.

Installation

PROCEDURE

1. Install the fuel filter and secure the bracket. Make sure the filter is positioned correctly. The arrow on the filter housing points in the direction of fuel flow, i.e., toward the engine. Refer to the accompanying illustration.
2. Install the fuel hoses onto the fuel filter connections (1) and (2) and secure them with clamps.

3. Remove the hose clamps.
4. Place the transmission in Neutral and apply the parking brake. Start the engine and check the fuel connections for leaks.
5. Install the covers and lower the vehicle to the wheels.

Water Draining and Replacement of the Diesel Engine Fuel Filter

The diesel engine fuel filter must be replaced every 40,000 km.

During Maintenance Service 1 (every 10,000 km, but at least once a year), water must be drained from the diesel engine fuel filter.

Water typically forms in the fuel tank as a result of condensation or enters with the fuel at the filling station.

The filter is located in the engine compartment, on the left side. A suitable container is required to collect the water.

* Diesel fuel that gets on rubber components (coolant hoses) must be wiped off immediately, otherwise the component will deteriorate over time.

Draining Water

PROCEDURE
1. Fit a suitable Ø 8 mm hose onto the drain fitting. Place a container under it to collect the fluid.

2. Unscrew nut (2) under the filter by hand, several turns. If the nut cannot be loosened by hand, a pipe wrench with a leather or cardboard pad may be used.
3. Up to approximately 200 cm3 of water may drain from the filter before clean fuel appears. Hand-tighten the water drain valve.
4. Disconnect the supply line to the injection pump at the top of the filter. Squeeze the clamp while doing so. Ask an assistant to start the engine until fuel flows from the filter. Stop the engine. This quickly purges air from the filter. Refer to the accompanying

* Place a suitable container to collect the spilled diesel fuel.

5. Install the fuel hose. Replace any damaged gasket. To ease installation of the hose, lubricate the fitting with petroleum jelly. Start the engine. Press the accelerator several times. Fuel free of air bubbles must flow through the transparent hose leading to the injection pump. Check the system for leaks.

Filter Replacement

PROCEDURE
1. Drain the fluid from the filter as when draining water.
2. Unscrew the fuel filter from the flange by hand. If the filter is very tight, use a strap wrench, for example HAZET 2170. Refer to the accompanying illustration.

3. If a strap wrench is not available, remove the two mounting bolts at the top of the filter and remove the filter with the flange. First disconnect the supply and return fuel hoses by squeezing the clamps. Also disconnect the plug connector of the filter flange heater. Clamp the flange in a vise.
21 Fill the new filter to the brim with fuel and screw it on by hand against the flange.

* Do not overtighten the filter. Once the gasket contacts the flange, turn the filter an additional half turn. Observe the instructions printed on the filter cover.

22 If removed, install the filter flange with the filter and connect the plug and fuel supply hose. Replace any damaged gasket. To ease installation, lubricate the gasket with petroleum jelly.
23 Ask an assistant to start the engine until fuel appears at the filter. Stop the engine. This quickly purges air from the filter.

* Collect the spilled diesel fuel.

24 Connect the fuel pump hose to the filter. Replace any damaged gasket. To ease installation, lubricate the gasket with petroleum jelly.
25 Start the engine. Press the accelerator several times. Fuel free of air bubbles must flow through the transparent hose leading to the injection pump. Check the system for leaks.