| : | Sep 21, 2005 |
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: 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. |
: 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. |
: 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.
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: 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. |
: 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.
|
: Do not disconnect the fuel injector electrical connectors with the
engine running. Failure to follow this instruction may result in serious
damage to the engine. |
: Always carry out the cleaning process before carrying out any repairs to
the fuel injection system components. Failure to follow this instruction
may result in foreign matter ingress to the fuel injection system.
|
: 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. |
: Do not disassemble the fuel injectors or clean the nozzles, even with an
ultrasonic cleaner. Always install new fuel injectors when required.
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| . | Disconnect the battery ground cable. |
| . | Remove the engine cover. |
| . | Disconnect the low-pressure fuel lines.
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| . | Disconnect both exhaust gas recirculation (EGR)
coolant cross-over pipe hoses.
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| . | Remove the EGR coolant cross-over pipe.
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| . | Remove the battery. |
| . |
:
Disconnect the three engine harness electrical connectors in the order shown. ![]() |
| . | Release the engine wiring harness from the
bulkhead. ![]() |
| . | Remove the injector sound proofing. |
| . | Disconnect the fuel injector electrical
connectors. ![]() |
| . | Release the engine wiring harness.
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| . |
Remove and discard the high-pressure fuel supply line.
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| . | Disconnect the fuel return line from the fuel
injector. ![]() |
| . | Remove the two fuel injector retaining bolts.
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| . | Install the special tool studs. ![]() |
| . |
Install the special tool remover legs to the studs. ![]() |
| . | Remove the fuel injector.
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| . |
Install a new fuel injector retaining clamp.
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| . | Install the fuel injector.
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| . |
Connect the fuel return line to the fuel injector.
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| . |
Install the new high-pressure fuel supply line.
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| . | Attach the engine wiring harness. |
| . | Connect the fuel injector electrical connectors. |
| . | Install the injector sound proofing. |
| . | Attach the engine wiring harness to the bulkhead. |
| . | Connect the three engine harness electrical connectors. |
| . | Install the battery. |
| . | Install the EGR coolant cross-over pipe.
|
| . | Connect both EGR coolant cross-over pipe hoses.
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| . | Connect the low-pressure fuel lines.
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| . | Install the engine cover. |
| . | Connect the battery ground cable. |
| . | Check and top-up the coolant. |
| . | Bleed the fuel system. |