Tube(S), Fuel, High Pressure: Removal
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, 206 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.
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.
- Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
- Remove the engine cover. Refer to the appropriate service information article.
.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.
CAUTION:DO NOT crimp or bend the high pressure fuel tubes.
NOTE:After removing fuel tubes from the fuel system, be certain to seal the connections to maintain and ensure system cleanliness.
- Unscrew the union nuts (1 and 3) and the discard fuel tubes (2).CAUTION:
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.
- Unscrew the union nuts (1) at the fuel rail.
- Using a wrench to counter hold fitting, unscrew the union nut (3) from the fuel injection pump outlet port and discard the fuel tube (2).