Fuel Pressure Control Solenoid: Service and Repair

WARNING:
- HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 1600BAR (23,200 PSI). USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH. INSPECT FOR HIGH-PRESSURE LEAKS WITH A SHEET OF CARD BOARD. WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM.
- 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.

REMOVAL
1. Disconnect negative battery cable.
2. Remove fuel rail.
3. Clamp fuel rail securely in vise with protective jaws.

NOTE: Once removed, the pressure solenoid must always be replaced.

Fuel Pressure Solenoid Assembly:

4. Remove fuel pressure solenoid retaining screws and remove solenoid.

INSTALLATION

NOTE: Apply a thin film of special grease to the seals before installing. If the seals are damaged when being installed, an internal leak may occur which can not be recognized externally.

1. Position fuel pressure solenoid to fuel rail and retain with screws . Tighten in two stages, 3 N.m (26 lbs. in.) then 5 N.m (44 lbs. ft.).
2. Install fuel rail.
3. Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS, OR FAN. DO NOT WEAR LOOSE CLOTHES.

4. Start engine and inspect for leaks.