Page 33 of 100
Fuel Priming
In order for the fuel system to work properly, the fuel lines
must be full of fuel and contain no air. If air gets into the
fuel lines, it will be necessary to prime the fuel lines, to
eliminate air before operating the vehicle.
Q:How does air get into the fuel lines?
A:One of the following may have happened:
•The vehicle ran out of fuel
•The fuel filter was removed for servicing or
replacement
•The fuel lines were removed or disconnected for
servicing
•The fuel filter water drain valve was opened while
the engine was running
If one or more of the above occur, it is very likely that
air has entered your fuel system and that you will need
to prime the fuel system before operating the vehicle.
Air in the fuel lines will not harm the engine or the
vehicle.However, the engine may not be able to start until the
fuel system is primed and the air is removed.
Q:How do I prime the vehicle? (Pickup Models)
A:Your vehicle is equipped with a priming pump which
is part of the engine mounted fuel filter. The priming
pump is hand operated (pickup only) and is designed
to bring fuel to the engine to eliminate any air that
may be in the fuel lines. To prime the engine, do the
following:
1. You must correct the condition which caused the loss
of prime by making sure there is fuel in the tank.
2. Make sure the fuel filter has been installed and
properly tightened.
3. Make sure the fuel lines are properly connected
and the fuel filter is cool enough to touch.
4. Remove any dirt from the fuel filter head and vent
valve by wiping with a cloth.
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5. Open the fuel filter vent
valve by turning the
screw counterclockwise
several full turns. The
vent valve is located
on top of the fuel filter
housing.
6. Repeatedly push down
on the fuel filter priming
pump with the palm of
your hand. The pump
is located on top of the
fuel filter housing. Let
the pump return upward
between pushes.7. Operate the priming pump until a small amount of
fuel seeps from the vent valve. When you see the
fuel, the filter is now full of fuel and the system
should be primed.
8. Close the vent valve. Clean any fuel which
accumulated on the fuel filter. Start the engine and
let idle for a few minutes. Check the filter for leaks.
Q:How do I prime the vehicle? (Van Models)
A:Your vehicle is equipped with an electric priming
pump which is located in front of the fuel tank
under your vehicle. The priming pump is operated
electrically and is designed to bring fuel to the engine
to eliminate any air that may be in the fuel lines.
To prime the engine, do the following:
1. Turn the ignition key on for two minutes. The fuel
pump will be operating and starting the priming
process. Do not start the engine during the first
two minutes.
2. After completing the initial prime in Step 1, turn the
ignition off, then back to start and crank the engine
for 15 seconds.
3. If the engine does not start, repeat Steps 1 and 2
until the engine starts.
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4. If the engine does not run after repeating Steps 1
and 2 three times, turn the ignition key off for
60 seconds, allowing the Electronic Control
Module (ECM) to reset.
5. Repeat the above steps until the engine starts.
6. If the engine runs, but does not run smoothly,
increase the engine speed slightly by pressing
the accelerator pedal. This will help to force
out air through the system.
7. If the engine starts and runs but stalls again, turn the
ignition key off for 60 seconds to reset the ECM and
repeat the steps above.
8. When the engine starts, let it idle for a few minutes
and check the filters for any leaks.Running Out of Fuel
Pickup Models
If the engine stalls and you think that you have run out
of fuel, do this to restart your engine:
{CAUTION:
Diesel fuel is ammable. It could start a re if it
gets on hot engine parts. You could be burned.
Do not let too much fuel ow from the air bleed
valve, and wipe up any spilled fuel with a cloth.
1. If you are parked on a level surface, add at least
two gallons of fuel. However, if you are parked on a
slope, you may need to add up to five gallons of fuel.
2. Follow the fuel priming procedure earlier in this
section to prime the fuel filter.
3. Close the air bleed valve.
4. Turn the ignition key to START for 10 to 15 seconds
at a time until your engine starts. If the engine tries to
run, but does not run smoothly, increase the rpm a
little using the accelerator pedal. This will help force
air through the system.
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Van Models
If the engine stalls and you think that you may have run
out of fuel, do this to restart your engine:
1. If you are parked on a level surface, add at least
one gallon of fuel. However, if you are parked on a
slope, you may need to add up to five gallons of fuel.
2. Follow the vehicle fuel system priming procedure
earlier in this section to re-prime the system and
re-start the engine.
Your check engine light may come on if the vehicle has
run out of fuel. This light may stay on for a few drive
cycles after the condition is corrected, but will eventually
clear itself.
Fuel Filter Replacement
Pickup Models
If you want to change the fuel filter yourself, here’s how
to do it:
{CAUTION:
Diesel fuel is ammable. It could start a re if
something ignites it, and you could be burned.
Do not let it get on hot engine parts, and keep
matches or other ignition sources away.
First, drain any water from the filter following the
procedure for draining water listed previously.
Your vehicle’s engine should be off until the end of this
procedure.
The fuel filter is located in the engine compartment on
the passenger’s side of the vehicle, or on the driver’s
side frame rail in front of the fuel tank.
1. Apply the parking brake.
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2. Unplug the water
sensor wire connected
to the fuel filter and
unscrew the filter
element.
3. Remove the filter element. If there is any dirt on the
filter sealing surface, clean it off. Remove and reuse
the water sensor float switch located on the bottom of
the fuel filter.
4. Install the new filter element.
5. Reinstall and tighten the filter container and
reconnect the water sensor wire to the filter.
6. Use the fuel filter priming procedure earlier in this
section to prime the fuel filter.
7. Tighten the air bleed valve by turning it clockwise
until hand tight.
8. Start your engine and let it idle for five minutes.
Check your fuel filter and air bleed valve for leaks.9. Reset the fuel filter monitor. SeeDriver Information
Center (DIC) (Pickup Models Only) on page 3-9for
more information.
Van Models
If your fuel operated heater (FOH) is not working, your
FOH line requires priming. See your dealer for service.
SeeFuel Operated Heater (FOH) (Van Models Only) on
page 2-8for more information.
If you want to change the fuel filter yourself, here’s how
to do it:
{CAUTION:
Diesel fuel is ammable. It could start a re if
something ignites it, and you could be burned.
Do not let it get on hot engine parts, and keep
matches or other ignition sources away.
First, drain any water from the filter following the
procedure for draining water listed previously.
Your vehicle’s engine should be off until the end of this
procedure.
The fuel filters are located on the driver’s side frame rail
in front of the fuel tank.
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Primary Filter (A)
1. Apply the parking brake.
2. Unplug the water sensor wire connected to the fuel
filter (lowest wire) and unscrew the filter’s cap.
3. Remove the filter element. If there is any dirt on the
filter sealing surface, clean it off.4. Install the new filter element.
5. Reinstall and tighten the filter’s cap and reconnect
the water sensor wire to the filter.
6. Prime the fuel system.
7. Start your engine and let it idle for five minutes.
Secondary Filter (B)
1. Apply the parking brake.
2. Unscrew the filter element.
3. Remove the filter element. If there is any dirt on the
filter sealing surface, clean it off. Remove and reuse
the water drain valve located at the bottom of the
fuel filter.
4. Install and tighten the new filter element.
5. Prime the fuel system.
6. Start your vehicle and let it idle for five minutes.
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Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to you
and others, read and follow all the instructions
on the pump island. Turn off your engine when
you are refueling. Do not smoke if you are near
fuel or refueling your vehicle. Keep sparks,
ames, and smoking materials away from fuel.
Do not leave the fuel pump unattended when
refueling your vehicle — this is against the law
in some places. Keep children away from the
fuel pump; never let children pump fuel.The fuel cap is located behind a hinged door on the
driver’s side of the vehicle.
For chassis-cab models, refuel the front tank first,
or in instances when only a partial fuel fill is desired.
An automatic transfer mechanism will maintain
approximately equal fuel levels in both tanks,
so no switching is required by the operator.
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To remove the fuel cap, turn it slowly to the left
(counterclockwise).
{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly. This
spray can happen if your tank is nearly full, and
is more likely in hot weather. Open the fuel cap
slowly and wait for any hiss noise to stop. Then
unscrew the cap all the way.Be careful not to spill diesel fuel. Don’t top off or overfill
your tank, and wait a few seconds after you’ve finished
pumping before you remove the nozzle. Clean fuel from
painted surfaces as soon as possible. See “Washing
Your Vehicle” in your owner’s manual. When you put the
fuel cap back on, turn it to the right (clockwise) until you
hear a clicking sound. Make sure you fully install the cap.
The diagnostic system can determine if the fuel cap has
been left off or improperly installed. This would allow fuel
to evaporate into the atmosphere. SeeMalfunction
Indicator Lamp on page 3-4.
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