Removal Procedure
WARNING: This page is about a different variant/trim than selected.
WARNING:
Refer to Safety Goggles and Fuel Warning
WARNING:
Refer to Diesel/Gasoline Vapors Warning
WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
- Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (KL9)
- Remove Intake Manifold Cover. Refer to Intake Manifold Cover Replacement
- Remove Fuel Injection Fuel Feed Pipe. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail
- Disconnect the electrical connectors:
- Intake Manifold Runner Control Valve Actuator (1)
- Fuel Rail Pressure Sensor (2)
- Intake Air Pressure and Temperature Sensor (3)
- Fuel Pressure Regulator (4)
- Exhaust Temperature Sensor - Position 1 (5)
- Glow Plugs (7) (Qty: 4)
- Unclip Wiring Harness Retainers (6, 8) (Qty: 4)
- Disconnect Fuel Return Front Pipe (1) @ Diesel Fuel Separator (2). Refer to Metal Collar Quick Connect Fitting Service
- Close all open connections with the suitable closure plugs.
- Disengage Diesel Fuel Separator Hose Clamp (5)
- Disconnect Diesel Fuel Separator Hose (4) @ Fuel Rail
- Remove and DISCARD Clamp (6)
- Disconnect Fuel Return Hose (7) @ Diesel Fuel Separator (2)
- Remove Diesel Fuel Separator Bolt (3)
- Remove Engine Wiring Harness Conduit Bolts (1) (Qty: 3)
- Disconnect Diesel Fuel Separator (2) @ Fuel Injection Pump (1). Refer to Plastic Collar Quick Connect Fitting Service
- Close all open connections with the suitable closure plugs.
- Remove the diesel fuel separator (1) by rotating clockwise while pulling up the diesel fuel separator.