Removal and Replacement

REMOVAL

WARNING: NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

1. Disconnect negative battery cable.
2. Partially drain cooling system from radiator only.
3. Remove thermostat housing.
4. Disconnect engine wiring electrical connectors from sensors restricting harness movement.
5. Remove engine harness retaining bolts.
6. Remove fuel temperature sensor from fuel rail.
7. Remove fuel rail retaining bolts and disconnect glow plug connectors.
8. Remove front engine lift support.

CAUTION: When slackening and tightening fuel injection line union nuts, counter hold with wrench at threaded connection. ON NO ACCOUNT exceed the tightening torque at any time. Do NOT crimp or bend lines.

NOTE: After removing lines, seal connections and ensure cleanliness.

Fuel Pressure Solenoid:

9. Remove injector high pressure lines.
10. Remove pressure line of high pressure pump.
11. Detach fuel return flow line to high pressure pump at rail.
12. Detach fuel return flow line to fuel filter at fuel filter.
13. Remove fuel rail.

INSTALLATION

WARNING: NO FIRE, FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

1. Loosely position fuel rail into position on cylinder head.
2. Position and loosely install fuel return line from fuel filter, with new seals to rail.
3. Position fuel rail to cylinder head, feed in high pressure line with new seals.

CAUTION: Inspect sealing cones at the lines. Replace as necessary. Ensure that all fuel pressure lines are exactly located in original position.

4. Hand start all injector lines.

CAUTION: When tightening fuel injection line union nuts, counter hold with a wrench at the thread connection. ON NO ACCOUNT exceed the tightening torque at any time.

5. Tighten fuel rail bolts to 14 N.m (124 lbs.in.).
6. Tighten nut of pressure line to rail/injector to 22 N.m (194 lbs.in.).
7. Tighten nut of pressure line to high pressure pump/rail to 22 N.m (194 lbs.in.).
8. Tighten banjo bolt of fuel return line to fuel rail to 20 N.m (177 lbs.in.).
9. Install fuel temperature sensor.
10. Install front engine support lift.
11. Install thermostat housing.
12. Reconnect engine harness electrical connectors.
13. Refill cooling system.
14. Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

15. Start engine and inspect for leaks.