| : | Apr 26, 2006 |
: 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. |
: 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.
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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.
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: 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.
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: 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 remove the FRP sensor from the fuel diverter rail.
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| The fuel diverter rail and fuel rail pressure (FRP) sensor are supplied as a complete assembly only. The FRP sensor must not be removed from the diverter rail. If a new FRP sensor is required, the fuel diverter rail must renewed as an assembly. |
| . | 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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| . |
:
Release the RH and LH high-pressure fuel supply lines.
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| . |
:
Remove and discard the RH and LH high-pressure fuel supply lines.
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| . |
:
Remove and discard the high-pressure fuel supply line.
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| . | Release the low-pressure fuel line.
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| . | Disconnect the fuel rail pressure (FRP) sensor
electrical connector.
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| . | Remove the fuel diverter rail assembly.
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: Do not remove the FRP sensor from the fuel diverter rail.
|
| The fuel diverter rail and FRP sensor are supplied as a complete assembly only. The FRP sensor must not be removed from the diverter rail. If a new FRP sensor is required, the fuel diverter rail must renewed as an assembly. |
| . | Install the FRP sensor and fuel diverter rail
assembly.
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| . | Connect the FRP sensor electrical connector.
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| . | Install the new high-pressure fuel supply line.
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| . | Attach the low-pressure fuel line.
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| . | Install the new RH and LH high-pressure fuel
supply lines.
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| . | Secure the high-pressure fuel supply lines.
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| . | Install the EGR coolant cross-over pipe.
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| . | 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. |
| . | Bleed the fuel system. |
| . | Check and top-up the coolant. |