| : | Aug 5, 2004 |
: Do not carry or operate cellular phones when working on or near any fuel
related components. Highly flammable vapors are always present and may
ignite. Failure to follow these instructions may result in personal
injury. |
: Do not carry out any repairs to the fuel system with the engine running.
The fuel pressure within the system can be as high as 1650 bar (23,931
lb-sq-in). Failure to follow this instruction may result in personal
injury. |
: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable vapors
are always present and may ignite. Failure to follow these instructions
may result in personal injury. |
: This procedure involves fuel handling. Be prepared for fuel spillage at
all times and always observe fuel handling precautions. Failure to follow
these instructions may result in personal injury.
|
: Wait at least 30 seconds after the engine stops before commencing any
repair to the high-pressure fuel injection system. Failure to follow this
instruction may result in personal injury. |
: Before disconnecting or removing components, ensure the area around the
joint faces and connections are clean. Plug open connections to prevent
contamination. |
: Diesel fuel injection equipment is manufactured to very precise
tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always install
blanking plugs to any open orifices or lines. Failure to follow this
instruction may result in foreign matter ingress to the fuel injection
system. |
: Make sure the workshop area in which the vehicle is being worked on is
as clean and as dust free as possible. Foreign matter from work on
clutches, brakes or from machining or welding operations can contaminate
the fuel system and may result in later malfunction.
|
| . | Disconnect the battery ground cable. |
| . | Drain the cooling system. |
| . | Remove the crankcase vent oil separator. |
| . | Release the coolant bleed hose from the LH
exhaust gas recirculation (EGR) coolant inlet hose.
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| . | Remove the cylinder head coolant elbow.
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| . | Disconnect the knock sensors (KS) electrical
connector.
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| . | Remove the LH KS.
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| . |
:
Remove the oil cooler.
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| . |
:
Install the oil cooler.
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| . | Install the LH KS.
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| . | Install the cylinder head coolant outlet elbow.
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| . | Secure the coolant bleed hose to the EGR coolant inlet hose. |
| . | Install the crankcase vent oil separator. |
| . | Connect the battery ground cable. |
| . | Refill and bleed the cooling system. |
| . | Check and top-up the engine oil. |