High Pressure Lines

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

High Pressure Lines At Injectors:

1. Disconnect negative battery cable.

CAUTION:
- Counterhold with wrench at threaded connections of injectors. DO NOT EXCEED the tightening torque in order to avoid also slackings the threaded connection.
- DO NOT crimp or bend lines.

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

2. Unscrew union nuts of injection lines.
3. Remove injection lines.

INSTALLATION

1. Loosen the fuel rail mounting bolts to install lines free of stress.

CAUTION: Inspect sealing cone at lines. Replace if compression points exist. Ensure lines are exactly located.

2. Position and install fuel lines.Tighten to 22 N.m (195 lbs.in.) using a wrench to counterhold at threaded connection.
3. Tighten fuel rail to 14 N.m (124 lbs.in.).
4. Connect negative battery cable.

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

5. Start engine and inspect for leaks.