| : | Sep 21, 2005 |
: 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 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 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.
|
: 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. |
| . | Disconnect the battery ground cable. |
| . | Remove the intake air shutoff throttle. |
| . | Release the glow plug harness from the valve
cover. ![]() |
| . | Release the knock sensor (KS) harness from the
valve cover. ![]() |
| . | Disconnect the KS electrical connector. ![]() |
| . | Disconnect the valve cover breather hose.
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| . | Remove the fuel injector. |
| . | Remove the remaining fuel injectors. |
| . | Release the high-pressure fuel supply line.
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| . |
Remove and discard the high-pressure fuel supply line.
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| . | Remove the fuel injection supply manifold.
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| . | Detach the fuel lines. ![]() |
| . | Remove the fuel line securing bracket.
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| . | Remove the fuel injection supply manifold
securing bracket.
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| . | Remove the engine cover locating studs. ![]() |
| . | Remove the RH valve cover.
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| . | Install the RH valve cover.
|
| . | Install the engine cover locating studs. |
| . | Install the fuel injection supply manifold
securing bracket.
|
| . | Install the fuel line retaining bracket.
|
| . | Attach the fuel lines to the retaining bracket. |
| . | Install the fuel injection supply manifold.
|
| . | Install a new high-pressure fuel supply line.
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| . | Secure the high-pressure fuel supply line.
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| . | Install the fuel injector. |
| . | Install the remaining fuel injectors. |
| . | Connect the valve cover breather hose. |
| . | Connect the KS electrical connector. |
| . | Attach the glow plug harness and KS harness to the valve cover. |
| . | Install the intake air shutoff throttle. |
| . | Connect the battery ground cable. |