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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 before the removal procedure. Ensure that the area surrounding the fuel lines is 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. |
Note: The following procedures were written for the complete removal of all fuel lines and clamps. If specific fuel lines need to be replaced, then only remove those fuel lines and clamps that need replacement.
- Turn the fuel supply to the OFF position.
- Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Disconnect".
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Illustration 1 g06076725 - Remove nuts (1) and remove clamps (6). Loosen nut (4) and nut (5). Loosen nut (7) and nut (8). Remove fuel line assembly (2) and fuel line assembly (3) and discard.
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Illustration 2 g06076762 - Disconnect harness assembly (9). Remove bolts (10) and remove fuel pressure sensor (11). Loosen nut (12) and nut (16). Remove tube assembly (17). Loosen nut (13) and nut (15). Remove tube assembly (14).
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Illustration 3 g06076817 - Remove P-clip (20) and P-clip (21). Loosen nut (18) and nut (25). Remove tube assembly (22). Remove nut (19) and nut (23). Remove tube assembly (24).
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Illustration 4 g06076943 - Loosen nut (27) and nut (28). Remove tube assembly (26). Remove nut (31) and nut (33). Remove tube assembly (32). Remove bolts (29) and remove socket (30).
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Illustration 5 g06076974 - Remove P-clip (37). Remove nut (34) and nut (36). Remove tube assembly (35).
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Illustration 6 g06078116 - Disconnect harness assembly (39). Remove bolts (41) and remove plate (38). Remove valve mechanism cover (40).
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Illustration 7 g06078283 - Remove two bolts (42) and remove two mounting brackets (43). Remove fuel line assemblies (47), (48), (49), (50), (51), (52), (53), and (54) and discard. Remove unions (44), adapter (45), and adapter (46).
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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 fuel line caps 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.
- Install the tube assemblies in the reverse order of removal.
- Tighten tube assemblies (54), (53), (52), (51), (50), (49), (48), and (47) to a torque of
42 ± 2 N·m (31 ± 2lb ft) . - Replace and tighten adapter (46) to a torque of
55 ± 5 N·m (41 ± 4 lb ft) . - Replace and tighten adapter (45) to a torque of
50 ± 5 N·m (37 ± 4 lb ft) . - Replace and tighten unions (44) to a torque of
65 ± 7 N·m (48 ± 5 lb ft) . - Tighten bolts (42) to a torque of
25 ± 3 N·m (221 ± 27 lb in) .Show/hide table
Illustration 8 g06078236 - Tighten bolts (41) to a torque of
9 ± 1 N·m (80 ± 9 lb in) in the order depicted in Illustration 8. - Tighten P-clip (37) to a torque of
25 ± 3 N·m (221 ± 27 lb in) . - Tighten nut (36) to a torque of
40 ± 4 N·m (30± 3 lb ft) . - Tighten nut (34) to a torque of
40 ± 4 N·m (30± 3 lb ft) . - Tighten nut (33) to a torque of
40 ± 4 N·m (30± 3 lb ft) . - Tighten nut (31) to a torque of
40 ± 4 N·m (30± 3 lb ft) . - Tighten bolts (29) to a torque of
25 ± 3 N·m (221 ± 27 lb in) . - Tighten nut (28) to a torque of
40 ± 4 N·m (30± 3 lb ft) . - Tighten nut (27) to a torque of
40 ± 4 N·m (30± 3 lb ft) . - Tighten nut (25) to a torque of
43 ± 3 N·m (32 ± 2 lb ft) . - Tighten nut (23) to a torque of
43 ± 3 N·m () . - Tighten P-clip (21) to a torque of
25 ± 3 N·m (221 ± 27 lb in) . - Tighten P-clip (20) to a torque of
25 ± 3 N·m (221 ± 27 lb in) . - Tighten nut (19) to a torque of
43 ± 3 N·m (32 ± 2 lb ft) . - Tighten nut (18) to a torque of
43 ± 3 N·m (32 ± 2 lb ft) . - Tighten nut (16) to a torque of
50 ± 5 N·m (37 ± 4 lb ft) . - Tighten nut (15) to a torque of
50 ± 5 N·m (37 ± 4 lb ft) . - Tighten nut (13) to a torque of
50 ± 5 N·m (37 ± 4 lb ft) . - Tighten nut (12) to a torque of
50 ± 5 N·m (37 ± 4 lb ft) . - Tighten bolts (10) to a torque of
10 ± 1 N·m (89 ± 9 lb in) . - Replace fuel line assembly (2) and fuel line assembly (3). Tighten nuts (8), (7), (5), and (4) to a torque of
42 ± 2 N·m (31 ± 1 lb ft) . - Tighten nuts (1) to a torque of
25 ± 3 N·m (221 ± 27 lb in) .
- Tighten tube assemblies (54), (53), (52), (51), (50), (49), (48), and (47) to a torque of
