Removal Procedure
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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
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Cleanliness is an important factor. Clean the exterior of the engine thoroughly before the removal procedure. Ensure the area around the Fuel Manifold and the Fuel Lines are thoroughly cleaned. This action will prevent contaminants from entering the internal mechanism. Before replacing any Fuel Lines, follow the instructions that are listed below. Replace the Fuel Lines with the correct Fuel Lines Group. |
- Turn the fuel supply to the OFF position.
- Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
- Remove all components in order to access to the wiring harness.
- Loosen clamp assemblies (1) and remove hose (2) .
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| Illustration 1 | g02140798 |
- Disconnect fittings (3) and (7) .
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| Illustration 2 | g02140852 |
- Remove bolts (5) , (6) , and (8) and remove tube assembly (4) .
- Remove bolt (9) .
- Remove nuts (10) and remove bracket (11) .
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| Illustration 3 | g02140971 |
- Disconnect harness assemblies (12) .
- Position harness assembly (13) out of the way. Remove the spacers (not shown) from studs (14) .
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| Illustration 4 | g02141119 |
- Remove the bolt (15) and remove the clamp assembly. Discard the clamp assembly.
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| Illustration 5 | g02141131 |
- Remove nuts (23) , (19) , and (20) . Remove the corresponding clamp assemblies and discard the clamp assemblies.
- Loosen nuts (16) and (18) . Remove fuel line (17) and discard the fuel line. Repeat for the remaining fuel lines.
- Loosen nuts (21) and (24) . Remove fuel line (22) and discard the fuel line.
- Disconnect tube assembly (26) .
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| Illustration 6 | g02147909 |
- Remove studs (14) and remove fuel manifold (25) .
Installation Procedure
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Fuel injection lines MUST only be used once. Discard all fuel injection lines after use. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Make sure that the caps for the fuel lines remain in position until the fuel line is positioned near the corresponding ports to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
- Position fuel manifold (25) and install studs (14) hand tight. Connect tube assembly (26) .
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| Illustration 7 | g02147909 |
- Install a new fuel line (17) . Hand tighten nuts (16) and (18) on each end of the fuel line. Repeat for the remaining fuel lines.
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| Illustration 8 | g02141131 |
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| Illustration 9 | g02141119 |
Note: During installation, make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports. This action will prevent contamination.
- Install a new fuel line (22) . Hand tighten nuts (21) and (24) .
- Position the clamp assembly and install bolt (15) . Hand tighten the bolt.The fuel line could fail if the grommet is not correctly placed on the fuel line.
- Position the clamp assembly and install nuts (23) , (19) , and (20) . Hand tighten the nuts. The fuel line could fail if the grommet is not correctly placed on the fuel line.
- Tighten nuts (24) and (18) at the fuel rail to a torque of 27 ± 3 N·m (239 ± 27 lb in).
Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel lines.
- Tighten studs (14) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
- Tighten nuts (21) and (16) to a torque of 15 ± 3 N·m (135 ± 27 lb in). Turn nuts (10) and (5) for an additional 60 ± 5 degrees.
- Tighten bolt (15) and nuts (23) , (19) , and (20) to a torque of 12 ± 3 N·m (105 ± 27 lb in).
- Position the spacers (not shown) and harness (13) onto studs (14) .
- Install bracket (11) and install nuts (10) .
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| Illustration 10 | g02140971 |
- Connect harness assemblies (12) .
- Position tube assembly (4) . Connect fittings (3) and (7) . Install bolts (5) , (6) , and (8) .
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| Illustration 11 | g02140852 |
- Install bolt (9) .
- Position hose (2) and install clamp assemblies (1) .
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| Illustration 12 | g02140798 |
- Connect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Connect".
- Turn the fuel supply to the ON position.