Tube(S), Fuel, High Pressure: Installation
Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.
High pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel rail and from the fuel rail to the fuel injectors. This pressure may be as high as 1600 bar (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 fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing the high pressure circuits of the fuel system.
Counter hold union connections with a wrench and DO NOT EXCEED the recommended tightening torque in order to avoid also loosening the threaded connection between the union and the fuel injection pump.
DO NOT crimp or bend the high pressure fuel tubes.
High pressure fuel tubes from the fuel injection pressure pump to the fuel rail or from the fuel rail to the fuel injector must be replaced with NEW units if removed.
- Loosen the fuel rail mounting screws to ease the positioning of the new high pressure fuel tube.
- Position the NEW
fuel tube between the fuel injection pressure pump and the fuel rail. Tighten the union nuts to:
- Step 1 Tighten the union nut (1) at fuel rail to the proper torque. Refer to TORQUE SPECIFICATIONS .
- Step 2 Using a wrench to counter hold fitting, tighten the union nut (3) at the high pressure pump to the proper torque. Refer to TORQUE SPECIFICATIONS .
CAUTION:Counter hold union connections with a wrench at the fuel injectors. DO NOT EXCEED the recommended tightening torque in order to avoid also loosening the threaded connection between the union and the fuel injector.
- Position the NEW
fuel tubes (2) between the fuel injectors and the fuel rail. Tighten the union nuts to:
- Step 1 Tighten the union nut at fuel rail (1) to the proper torque. Refer to TORQUE SPECIFICATIONS .
- Step 2 Tighten the union nut at fuel injector (3) to the proper torque. Refer to TORQUE SPECIFICATIONS .
- Tighten the fuel rail mounting screws to the proper torque. Refer to TORQUE SPECIFICATIONS .
- Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
- Start the engine and inspect all of the high pressure fuel tube connections for leaks.
- Install the engine cover. Refer to the appropriate service information article .