Section 2.9 Fuel Filter

Section 2.9
Fuel Filter

The removal and installation procedures are the same for the non-EGR and EGR fuel filter element.‪

Section 2.9.1
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.‪

  1. Disconnect the batteries.
  2. Open the fuel tank fill cap to release pressure in the fuel system. Replace and tighten the cap.
  3. Clean the outside of the main fuel filter housing.
  4. Using a 36-mm socket, unscrew the cap on the main fuel filter housing. Remove the cap and lift the filter element a short distance within the filter housing and wait a minute or two allowing the fuel to drain off the filter. See Figure .
    Click to see this graphic in a separate window

     1. Filter Housing Cap‪

     3. Fuel Filter Element‪

     2. O-ring‪

     4. Filter housing‪

    Figure 1. Removing the Fuel Filter

  5. Remove the filter element from the cap and clean the fuel filter cap. Discard the filter element and the O-ring from the cap.

Section 2.9.2
Fuel Filter Installation

Install the fuel filter as follows:‪

  1. Lubricate the filter element rubber seal with a light coating of fuel oil and insert it into the filter housing. Push down and rotate the filter element while installing to ensure it is seated properly at the base of the housing.
  2. Fill fuel filter housing with clean fuel oil.

    Note: Note: A properly seated filter element will hold the fuel in the filter housing and prevent it from draining back to the tank. If the fuel does not stay in the housing the element is not seated properly, repeat steps 1 and 2.

  3. Install a new O-ring on the filter cap and screw the cap onto the filter housing. Tighten the cap to 25 N·m (18 lb·ft).
  4. If equipped with a hand pump on the fuel/water separator, work the hand pump until resistance is felt.

    Note: There should be a strong resistance in the hand pump, caused by the pressure build-up within the fuel system.

  5. Connect the batteries.
  6. 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.


    To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪



    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.
  7. Once the engine starts allow it to idle for at least one minute or until idle is smooth before applying the throttle. Check the fuel filter housing for leaks.
  8. If the engine will not start and run smoothly, prime the fuel system.

Note: DDC does not recommend opening the high-pressure fuel lines and bleeding the air from the fuel system as part of the priming process.

Note: MBE 4000 engines in March 2005 will be equipped with a fuel priming valve which is located in the secondary filter. Engines built before March 2005 require the installation of a fuel priming valve before using the Diesel Fuel System Primer tool (J-47912).

MBE 4000 Service Manual - 6SE412
Generated on 10-13-2008

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