| Required Tools | |||
| Tool | Pat Number | Part Description | Qty |
| A | 276-7018 | Plug/Cap Kit | 1 |
| B | - | Loctite 243 | - |
| C | - | Clean Engine Oil | - |
Note: All high-pressure fuel line connections to be closed with protective caps from Tooling (A)
| NOTICE |
|---|
|
Fuel injection lines can be reused if they remain with the same mating parts. The line(s) must be replaced if the quill or rail is replaced. |
| NOTICE |
|---|
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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.
- 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 g03827307 - Remove pressure sensor (1) and adapter assembly (2).
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Illustration 2 g03827312 - Remove bolt (3) and clamps (4).
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Illustration 3 g03827324 Note: All high-pressure fuel line connections to be closed with protective caps.
- Disconnect tube assembly (5), tube assembly (6), tube assembly (7), tube assembly (8), tube assembly (9), tube assembly (10), and tube assembly (11).
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Illustration 4 g03827336 - Disconnect tube assembly (14).
- Remove bolts (13) and fuel rail assembly (12).
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Illustration 5 g06371115 - Remove pressure sensor (15).
- Remove cap (16) and relief valve (not shown) .
- Install the fuel manifold in the reverse order of removal.
- Apply Tooling (C) to threads of relief valve.
- Install relief valve. Tighten the relief valve to a torque of
95 N m (+25 N m/-20 N m) . - Apply Tooling (B) to end threads of fuel rail assembly (12).
- Install cap (16). Tighten cap (16) to a torque of
45 ± 5 N·m (33 ± 4 lb ft) . - Apply Tooling (C) to threads and not washer of pressure sensor (15).
- Install pressure sensor (15). Tighten pressure (15) to a torque of
48 + 2 N·m (35 + 1 lb ft) . - Install fuel rail assembly (12) and hand tighten bolts (13) to the engine head.
- Lubricate the quill/rail nut side of tube assemblies (11) with Tooling (C).
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Illustration 6 g06371430 (17) Nut
(18) Nut
(19) O-Ring Seal
(20) Quill Nut
(21) Quill Tube - Hand tighten both ends of tube assemblies (11), beginning with the quill/pump end and then the rail end nut (17).
- Fully tighten bolts (13) with the outside bolts first.
- Tighten quill/pump nut (17) of tube assemblies (11) to a torque of
30 ± 3 N·m (266 ± 27 lb in) . - Tighten rail nut of tube assemblies (11) to a torque of
60 ± 4 N·m (44 ± 3 lb ft) . - Tighten quill/pump nut (18) of tube assemblies (11) to a final torque of
35 ± 3 N·m (29 ± 2 lb ft) . - Adjust clamps as necessary and tighten fully.
Note: No excessive force or bending should be required to properly assemble the fuel lines.
