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2 Service Champ Part Service Interval every 30,000 miles / Chevrolet liter Description and Operation The fuel filter element separates particles larger than 10 microns ( in) from fuel moving through it under lift pump pressure. Filter action is very critical to the operation of internal parts of the fuel injection pump. 2

3 FUEL MANAGER/FILTER The fuel manager/filter is an in-line type filter which combines several different functions. It acts as a fuel filter, water separator, water detector, water drain, and a fuel heater. The fuel manager/filter mounts on the rear of the intake manifold. The filter housing has an inlet fitting connecting to the pipe/hose from the lift pump and an outlet fitting connecting to the fuel injection pump with a hose. A third fining connects through a hose to a drain valve mounted on the water crossover/thermostat housing. The fuel manager/filter has a replaceable element. The element has an air vent valve on its top surface that is used during lift pump diagnosis and filter element replacement procedure. The fuel manager/filter also has a water in fuel sensor and a fuel heater. 3

4 Fuel Filter Replacement Procedures Remove engine cover/ intake manifold cover (4 bolts) to reveal the fuel filter location. 2. Fuel Filter housing will be visible (also noted as a fuel manager filter). 3. Remove the vehicles gas cap to depressurize the fuel pressure (if required). 4

5 4. Open the air bleed valve on top of the fuel manager/ filter to release any pressure in the fuel system. 5. Remove the element nut by turning it in a counterclockwise direction. If the nut is unable to turn by hand, use an oil filter wrench to loosen the nut. 6. Remove the filter by lifting, straight up and out of the filter assembly. It is not necessary to drain fuel from the filter assembly to change the filter element since the fuel will remain in the filter assemblies cavity. 5

6 7. Make sure the mating surface between the element assembly and the filter is clean before installation. Install the new filter by aligning the widest key slot located under the element assembly cap with the widest key in the header assembly. 8. Push the element in a downward direction until the mating surfaces make contact. Access can be difficult, due to the filter being at the back of the engine. When re-installing the filter it will be marked front and be indexed to only go on one way. The filter can not be fitted into the canister if it is not aligned properly. 6

7 9. Tighten the element nut securely by hand. 10. Reinstall the engine cover/ intake manifold cover (4 bolts) Tighten to 8ft/lbs. 11. Reinstall the fuel tank gas cap. 12. After the filter is installed turn the ignition key to run and leave it there for 15 seconds, then open the bleeder screw for a few seconds to purge any air. Before starting the engine up rinse any spilled fuel. 13. Cycle the engine (Key on, Key off, Key on, and then start). 14. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 15. The bleeder screw is made from fragile brass, be careful on the amount of torque applied when tightening or loosening the bleeder screw. 7

8 Service Champ Part Service Interval every 15,000 miles/ Ford liter Description and Operation OPERATION This vehicle utilizes a combination fuel filter/heater/water separator assembly. The assembly traps contaminants to ensure clean fuel is delivered to the injection pump, separate water from the fuel, and warms the fuel to prevent fuel line clogging due to wax formation. This vehicle is equipped with a fuel filter restriction sensor and warning lamp. The indicator is located in the instrument panel to alert the operator of a fuel filter restriction. If the indicator comes on during normal operation, replace the filter. COMPONENTS Fuel Filter/Restriction Sensor The fuel filter is of the spin on type. A sensor in the filter section activates an indicator when fuel flow through the filter is restricted and that the system requires service. Fuel Heater The fuel heater section warms the fuel to prevent wax formation and fuel system clogging when the temperature is below 30 f (-1.8 C). Water Separator The water separator operates on the principal that water is heavier than fuel, and will settle at the bottom of the assembly. There is a water-in-fuel probe located in the water separator section of the assembly. The probe activates a water-in-fuel indicator when approximately 0.1 quart (0.1 liter) of water has accumulated in the bowl. The engine should not be operated while the water-in-fuel indicator is on. The water separator should be drained every 5000 miles or when lamp illuminates. 8

9 Installation of Fuel Filter DRAINING: 1. Release the gas cap on the fuel filler tank to relieve fuel pressure. 2. Manually open drain valve by unscrewing. Allow drain valve to remain open approximately 15 seconds or until clear (water-free) diesel fuel flows from drain tube. 3. Close drain valve by threading into water separator drain bowl until liquid no longer drains from drain tube. CAUTION: Ensure that drain valve is fully and securely closed. 9

10 REMOVAL: 1. Remove water drain tube from bottom of filter assembly. 2. Unscrew water separator drain bowl and remove. 3. Unscrew fuel filter element and discard. INSTALLATION: 1. Clean gasket surfaces of the fuel filter adapter to prevent contamination. 2. Lightly coat filter sealing gaskets with clean diesel fuel. NOTE: To avoid fuel contamination do not add fuel directly to new filter. Allow engine to draw fuel through filter. 3. Screw new filter element onto filter base until seal contacts flange. 4. Tighten filter another 180 to 300 with a band wrench. 5. Install water separator drain bowl. Tighten another 180 to Install water drain tube. 7. Cycle the engine (Key on, Key off, Key on, and then start). 8. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. CAUTION: Ensure that drain valve is fully and securely closed. 9. Re-start the engine and make sure that water in fuel lamp does not glow. 10. Check for fuel leaks. 10

11 Service Champ Part Service Interval every 15,000 miles/ford Liter Description and Operation The Fuel Filter is located inside the fuel filter/water separator assembly on top of the engine. Remove fuel tank filler cap to relieve any pressure in the tank. CAUTION: Fuel supply tubes on vehicles with fuel injected engines will remain pressurized for long periods of time after engine shutdown. The pressure must first be relieved. Read all cautionary notes prior to relieving pressurized fuel system. 1. It may be necessary to remove the turbo charger compressor manifold to access the Fuel filter. 2. Release fuel filler gas cap to relieve any tank pressure. 3. Remove fuel filter cap. 4. Prime the fuel filter housing, before installing the new filter. 5. Replace filter element. 6. Replace O-ring with supplied replacement part. 7. Reinstall cap back onto housing and secure tightly to prevent leaking. 8. Tighten the fuel filler gas cap, before cycling the ignition (do not start), to purge the fuel system. 9. Cycle the engine (Key on, Key off, Key on, and then start). 10. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 11

12 Service Champ Part Service Interval every 15,000 miles/ford Liter Description and Operation Please note: After the service/ filter replacement - Restart the engine and check WATER IN FUEL indicator light. The light should not glow. If it continues to glow, have fuel system checked and repaired. When performing this service do not remove the upper line on the fuel filter housing to bleed off the pressure. The valve that the line connects to is aluminum and easily broken. IT DOES NOT NEED TO BE REMOVED TO PERFORM THIS SERVICE! 12

13 INSTALLATION: 1. Before beginning the service ensure you drain the fuel filter. 2. Release the fuel filler cap on the gas tank to relieve fuel system pressure. If the drain valve is accessible follow the instructions below, if not proceed to step number 4: 3. Open fuel filter drain valve by turning clockwise. Allow to drain for approximately 25 seconds or until clean fuel is observed. Close filter drain valve by turning counterclockwise until firmly seated. 4. Verify that the fuel filter drain valve is closed. 5. Remove the engine appearance cover. 6. Remove the fuel filter cap by turning counterclockwise. 7. Remove and discard old fuel filter element and fuel filter 0-ring. 8. Carefully clean the mating surfaces. 9. Apply a coating of clean diesel fuel to the new fuel filter 0-ring. 10. Install new fuel filter 0-ring onto fuel filter element. 11. Install new fuel filter and 0-ring into the fuel filter housing. 12. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into the fuel filter element. Priming is not necessary. 13. Tighten cap until it contacts the housing. 14. Tighten the fuel filler cap for the gas tank 15. Install engine appearance cover. Note: After replacing the fuel filter, the engine will purge the trapped air as it runs. The engine may run roughly and smoke until the air is completely eliminated. 16. Cycle the engine (Key on, Key off, Key on, and then start). 17. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 18. Restart the engine and check WATER IN FUEL indicator light. The light should not glow. If it continues to glow, have fuel system checked and repaired. 13

14 Service Champ Part Service Interval every 6,000 miles/ Dodge Cummins Liter Description and Operation The fuel/water separator filter is used to remove the water from the diesel fuel so that the fuel injection pump is not damaged. This assembly has a reservoir that holds the water, and it also has a Water-In-Fuel sensor to detect when service is required. After enough water has been collected, the Water-In-Fuel sensor will send a signal to the control module and the control module will illuminate the Water-In-Fuel Lamp. This assembly has a valve at the bottom of its reservoir to facilitate the removal of the water. To remove the water from the fuel/water filter separator, make sure the engine is not running and do the following: 1. Place an appropriate drain pan under the drain tube. 2. Push up on the drain to remove the water from the separator filter. 3. Hold the drain open until all of the water and contaminants are removed and clean diesel fuel flows out. The fuel/water separator filter is mounted in under the fuel heater. It is mounted to the driver s side of the engine. 14

15 Installation 1. Disconnect the water-in-filter sensor (WIF) electrical connection. 2. Remove the fuel filter assembly with a standard filter band wrench. NOTE: The fuel heater assembly should not move during the filter removal. 3. Remove the square cut 0-ring from the filter mounting bushing. 4. Drain fuel/water separator filter and remove WIF and fuel/water drain valve. NOTE: This assembly is threaded into the filter element and it is sealed with an 0-ring. 5. Install new square cut 0-ring on filter mounting bushing. Reinstall the WIF sensor into a new fuel filter element. 15

16 6. Reattach the sensor and wiring plug harness to the bottom of the new diesel filter. 7. The wiring harness plug can be difficult to attach due to its hidden location in the engine compartment. 8. Priming is necessary - Fill the new fuel water separator/filter with clean fuel. 16

17 9. Apply a light film of lubricating oil to the sealing surface before installing the filter. Inspect base plate surface for the old gasket Ensure that the wiring harness does not get pinched when re-attaching the new filter. 10. Install the fuel water separator/filter and tighten it 1/2 turn after its seal contacts the filter head. 11. Reconnect WIF electrical connection. (Note water sensor plugged in). 12. Before starting the vehicle use the lever on the fuel pump to prime it. 13. Cycle the engine (Key on, Key off, Key on, and then start). 14. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 17

18 Service Champ Part Service Interval every 15,000 miles / Dodge liter Description and Operation LOCATION: The fuel filter/water separator is located on the left side of the engine above the starter motor. The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The separator filter construction allows fuel to pass through it, but prevents moisture (water) from doing so. Moisture collects at the bottom of the separator filter. 18

19 The combination water-in-fuel sensor and fuel filter/water separator is screwed onto a metal housing located on the left/rear side of the engine and below the intake manifold. 19

20 REMOVAL: 1. Partially drain the filter/separator. 2. Remove the drain hose at the drain valve. 3. Disconnect the electrical connector from the WIF sensor at the bottom of the filter. 4. Remove (unscrew) the filter/separator and WIF sensor as one assembly from the filter housing. 20

21 5. Remove the 0-ring seal from the filter housing. 6. Drain the filter/separator. 7. Remove the WIF sensor, 0-ring and drain valve assembly from the filter/separator. 8. Inspect the WIF sensor probes. Clean contaminants from sensor probes if necessary. Replace sensor if probes will not clean up. 21

22 INSTALLATION: 1. Install a new 0-ring seal on WIF sensor. 2. Install WIF sensor/drain valve assembly into new filter/separator. NOTE: If the new fuel filter/water separator is not filled with clean fuel before it is installed, manual air bleeding of the fuel system may be necessary (Temporary rough engine running may occur). 3. Fill filter/separator with clean fuel. 4. Apply a light film of clean unused engine oil to the filter/separator seal. 5. Install a new 0-ring seal to the filter/separator housing. 6. Install filter/separator to housing. Tighten filter/separator one-half turn after it makes contact with the housing. Tighten by hand only. 7. Connect electrical connector to WIF sensor. 8. Connect drain hose to drain valve. 9. Cycle the engine (Key on, Key off, Key on, and then start). 10. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 22

23 Service Champ Part Service Interval every 6,000 miles/ Dodge Liter Description and Operation FUEL FILTER/WATER SEPARATOR: Whenever the fuel filter is being replaced, the pre-filter in the fuel heater assembly should be removed and cleaned. Refer to Fuel Heater Removal/Installation for procedures. The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains a fuel filter cartridge and Water-In-Fuel (WIF) sensor. REMOVAL: The canister drain valve serves two purposes. One is to partially drain the filter canister of excess water. The other is to completely drain the canister for filter replacement. DRAINING WATER FROM FILTER CANISTER: The filter should be drained whenever the water-in-fuel warning lamp remains illuminated. (Note that the 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. Place a drain pan under drain hose. With engine not running, rotate valve handle forward to DRAIN position. Hold drain valve open until all water and contaminants have been removed and clean fuel exits the drain hose. If fuel filter or WIF sensor is being replaced, drain the canister completely. Dispose of mixture in drain pan according to applicable regulations. After draining operation, rotate valve handle rearward to CLOSE position. If fuel filter or WIF sensor is being replaced, proceed to next step. 23

24 1. Remove drain hose at drain valve. 2. Disconnect Water-In-Fuel (WIF) sensor electrical connector pigtail harness from main engine wiring harness. The WIF sensor is located at side of filter canister. 3. Remove filter canister nut at top of header. 4. Lower canister assembly from header. 5. Remove and discard center O-ring. 6. Remove filter element (cartridge) from canister. 7. Remove WIF sensor and its seal from canister. 8. Inspect WIF sensor probes. Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up. 1. Clean inside of canister. 2. Install a new O-ring seal to WIF sensor. 3. Install WIF sensor to canister. Tighten to in. lbs. torque. 4. If drain valve assembly is being replaced, tighten mounting screws to in. lbs. torque. 5. Install new seal between canister and canister header. 24

25 NOTE: If filter canister is not filled with clean diesel fuel before installation, manual air bleeding of the fuel system may be necessary (temporary rough engine running may occur). If necessary, refer to the Air Bleed Procedure. 6. Fill filter canister with clean diesel fuel. 7. Apply a light film of clean diesel oil to seals. 8. Position canister assembly to canister header. Note that the locating tabs on canister should align into header tab on canister header. This step must be followed to prevent damage to canister or header and to prevent contact of drain valve into throttle linkage. 9. Install canister nut and tighten to 10 ft. lbs. torque. 10. Connect electrical connector to WIF sensor. 11. Connect drain hose to bottom of drain valve. 12. Cycle the engine (Key on, Key off, Key on, and then start). 13. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. AIR BLEED PROCEDURE NOTE: A certain amount of air becomes trapped in the fuel system when fuel system components are serviced or replaced. Bleed the system after fuel system service according to the following procedures. WARNING: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system. MANUAL BLEEDING: Some air enters the fuel system when the filters or injection pump supply line are changed. This small amount of air is vented automatically from the injection pump 25

26 through the fuel drain manifold. This is if the filter was changed according to instructions. The system may have to be bled manually if: The vehicle fuel tank has been allowed to run empty The fuel filter is not filled before installation The fuel injection pump is replaced High-pressure fuel line connections are loosened or lines replaced Initial engine start-up or start-up after an extended period of no engine operation. 1. Loosen the low-pressure bleed bolt. 2. Operate the rubber push-button primer on the fuel transfer pump. Do this until the fuel exiting the low-pressure bleed bolt is free of air. 3. Tighten low-pressure bleed screw to 6 ft. lbs. torque. FUEL INJECTION PUMP BLEEDING WARNING: The engine may start (when cranking) to bleed air from the injection pump. Place the transmission in neutral or park and set parking brake before engaging the starter motor. CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. 1. Perform the previous procedure: Manual Bleeding. 2. Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold. Observe the previous WARNING and CAUTION. 26

27 HIGH-PRESSURE FUEL LINE BLEEDING: WARNING: The fuel injection pump supplies high-pressure fuel as high as 17,405 psi (120,000 kpa) 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 highpressure fuel lines. WARNING: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system. Bleed air from one injector at time. 1. Loosen the high-pressure fuel line fitting at the injector. 2. Cycle the engine (Key on, Key off, Key on, and then start). 3. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 4. Crank the engine until all air is bled from the line. 1. Do not operate the starter motor for longer than 30 seconds. 2. Wait two minutes between cranking intervals. 5. Start the engine and bleed one injector at a time until the engine runs smoothly. 6. Tighten fuel line(s) at injector(s) to 22 ft. lbs. torque. 27

28 Service Champ Part Service Interval every 6,000 miles/ Dodge Cummins Liter Description and Operation 1. Once the cap is removed there will be an O-ring under the cap this will be replaced during the servicing of the fuel filter. 2. The filter will be attached to the cap with locking fingers carefully pry back a few fingers and remove the filter. 3. The filter housing will be located on the driver s side of the engine compartment. 28

29 Steps to Replacing the filter Look for the filter cap on the Drivers side of the engine compartment (to the left of the Brake fluid reservoir). 1. Prior to removing the filter cap, lower the level of diesel fuel by opening the water purge valve by turning it toward the fender of the truck. Let it drain for a few seconds and return the valve to its original position. Purge Valve 29

30 2. Open cap (an XL oil filter band wrench will help) Use caution as a wrench or ratchet may crack the lid nut (see diagram arrow #1). 3. Look for the o-ring as you remove the filter and cap together. 4. As stated above, the filter will be held onto the cap with locking fingers. Clean the inside of the cap. 5. Replace the fuel filter on the cap with the new part (hole in the filter should face downward. 30

31 6. Replace the O-ring with supplied part in box to the cap. 7. Clean the inside of the filter housing and remove any residual fuel/ water. 8. Fill the housing with new fuel before installing the cap and filter into place. If the housing is not primed, manual air bleeding may be necessary (temporary rough engine running may occur). 9. Apply a light film of clean diesel fuel to the cap o-ring seal. 10. Load filter and cap into the housing and tighten cap to 25ft lbs. Do not over tighten. Access to this area is tight due to restrictions in the engine bay. 11. Cycle the engine (Key on, Key off, Key on, and then start). 12. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 31

32 Service Champ Part Service Interval every 20,000 miles/ VW Liter Description and Operation (Diagram A) 1. Return Line (from injection pump) 2. Supply Line (to injection pump) 3. O-ring 4. Control Valve 5. Retaining clip 6. Return line (to fuel tank) 7. Supply line (from fuel tank) 8. Fuel filter 9. Gasket 10. Water drain plug 32

33 Replacing the Filter 1. Retaining clip 2. Control Valve (also has an O ring, that will be visible once removed) 3. Fuel Hose From Fuel tank 4. Fuel Hose To fuel pump Do not reverse the connection lines Direction of flow is indicated by arrows on the fuel filter Do not allow diesel fuel to come in contact with coolant hoses Steps to Replace the filter Remove retaining clip from valve (keep clip to reinstall). 2. Remove all 4 fuel line clips from the filter (Diagram A / 1, 2, 6 and 7). Remember the line connection points for reinstallation later. 3. Inspect valve and gaskets and replace if necessary (VW # ). 4. Prime the new filter with diesel fuel This will aid in the vehicle starting easier. 5. Reinstall new primed filter back into place. 6. Push the old valve or replacement valve back into place and attach fuel hose #3 and 4 with fuel line hose clamps. 7. Secure the old retaining clip on the valve. 8. Connect the 4 fuel lines back into place (Diagram A / 1, 2, 6 and 7). 9. Cycle the engine (Key on, Key off, Key on, and then start). 10. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. Fuel flowing through the transparent pipe must be free of bubbles. 33

34 Service Champ Part FD4604 Service Interval every 15,000 miles/ford Liter DSL Description and Operation FILTER: There are 2 filters located on this vehicle that need replacement. Both of the filters are included in the box. Locations: The Fuel filter is located on the frame rail underneath the vehicle and reachable by the lower technician. The Water separator filter is located in the engine compartment, and needs to be changed at the same time. REMOVAL: Fuel Filter 1. Stop the vehicle and shut off the engine. CAUTION: The vehicle must be stopped with the engine off when draining any of the 2 filters. Fuel may ignite if separator is drained while the engine is running or vehicle is moving. 2. Relieve the fuel system pressure. Release the vehicle fuel cap, prior to beginning any work. 3. Remove the drain plug, using a 6mm hex drive, by turning it counterclockwise. Allow the unit to drain for approximately 25 seconds or until clean fuel is observed. Install the drain plug by turning it clockwise until it is firmly seated. This step is not mandatory, but is suggested to prevent spillage. 34

35 4. Remove the cap on the housing. The cap will be facing the back of the vehicle. This will use a 36mm socket combined with a ½ inch extension. Note: You do not need to remove the fuel filter housing from the frame rail. The fuel filter will release and clip into the Fuel filter cap. 5. Replace the fuel filter with the new one and snap into place on the cap. Be sure to replace and inspect the cap seal. 6. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into the fuel filter element. Tighten cap until it contacts the housing. 7. Be careful not to over tighten the cap during installation. 8. Double check that the bleeder screw has been reinstalled and tightened 35

36 9. CAUTION: The vehicle must be stopped with the engine off when draining any of the 2 filters. Fuel may ignite if separator is drained while the engine is running or vehicle is moving. Once the diesel fuel filter has been changed, the second water separator filter requires replacement. 10. This filter is located in the engine compartment. Water separator Requires no pressure relief. 11. Use extreme caution when removing this cap as it can break, if over torqued. 12. Carefully clean the mating surfaces and replace the separator filter. Once the installation of both filters has been completed you are ready to start the engine. 13. The engine will not run properly if the fuel filter is not installed in housing. 14. After replacing the fuel filter, the engine will purge the trapped air as it runs. The engine may run roughly and smoke until the air is completely eliminated. 15. Cycle the engine (Key on, Key off, Key on) Restart the engine and check WATER IN FUEL indicator light; it should not be illuminated. If it continues to illuminate, have the fuel system checked and repaired. Note: Using a fuel which has more than average impurities may require the fuel filter to be replaced more frequently than the service interval specifies. 36

37 Service Champ Part LFF8736B Service Interval every 6,000 miles/chevrolet Liter Description and Operation Chevrolet 6.6 Liter Service Champ LFF8736B Note: 2 gaskets (Top and Bottom) Location: Passenger side Warning: There is a small bleeder screw (black plastic) this plastic screw is hex shaped and slotted. You must use a socket on this component as a flat head screw driver will damage this screw it can not be replaced, without replacing the entire assembly! Remove filter Note Wiring harness needs disconnection prior to filter removal. Computer sensor for water trap is located directly at the bottom of the filter. 37

38 Sensor plug Side by side comparison Note: Transfer water sensor / float to the new Filter. Inspect base plate surface for the old gasket. Ensure that the wiring harness does not get pinched when re-attaching the new filter. The wiring harness plug can be difficult to attach due to its hidden location. 38

39 The new filter requires priming. Approved containers must be used for diesel fuel storage. Access can be difficult due to restrictions in the engine bay area. New filter installed Engine view Before starting the engine, the filter top base has a priming pump function that will prime any remaining air A small bleeder screw requires loosening. This screw is made from fragile plastic, be careful on the amount of torque applied when tightening or loosening. 39

40 Warning: There is a small bleeder screw (black plastic) this plastic screw is hex shaped and slotted. You must use a socket on this component as a flat head screw driver will damage this screw it can not be replaced without replacing the entire assembly! Bleeding Screw Wiring harness Priming Pump Pushing the priming pump several times will eventually cause diesel fuel to seep out of the bleeding screw. Once fuel seeps, simply tighten the bleeder screw (See warning above). Ensure that all diesel fuel has been sufficiently cleaned up and washed down prior to starting the vehicle. 1. Cycle the engine (Key on, Key off, Key on, and then start). 2. Start engine and inspect for leaks. Operate the throttle several times to ensure adequate fuel flow. 40

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