- Ten-piece fuel rail guards isolate the high-pressure injection system from the engine compartment.
- For the system to function normally, it must consist of the following elements:
- two porous pads (1, fig. 4.63), that must be replaced if they are damaged or soaked in diesel fuel;
- lower protective element (2), made of sheet steel and secured between the fuel distribution line and the cylinder head;
- diesel fuel return pipes;
- rubber apron (3), attached to the sheet metal protective element and to the cylinder head cover;
- two side partitions (4);
- partitions (5), mounted on the cylinder head cover;
- two holders (6).
Pic. 4.63. Fuel distribution line protection elements: 1 - porous gaskets; 2 - lower protective element; 3 - rubber apron; 4 - side partitions; 5 - partition; 6 - holder
- During any work with elements of the fuel distribution line shields, care must be taken. so that after installing all the elements that make up this system, the latter are installed exactly in place.
Removal
- Disconnect the cable from the negative terminal of the battery
- Disconnect the connector from the air flow sensor.
- Remove the air filter housing and the sound insulation of the engine compartment partition. To remove the sound insulation, it is necessary, without disconnecting it, to remove the turbocharger pressure control solenoid valve installed on the partition of the engine compartment.
- Remove the expansion tank mounting bracket by disconnecting the preheating and postheating unit.
- Remove the fuel line at the turbocharger inlet. by disconnecting the crankcase ventilation system pipe.
- Remove the side partitions of the rubber apron. Disconnect the rubber apron from the engine mount, and then from the cylinder head cover and move the rubber apron back as far as possible.
- While holding the studs, unscrew the two nuts, remove the cylinder head cover sealing baffle and remove the porous absorbent gaskets.
- Disconnect the connector from the pressure sensor (1. Fig 4.58).
- Disconnect the rubber hose (2) return of diesel fuel from the injectors.
- Remove the fuel injection pipes (3), connecting the high pressure pump and the fuel distribution line. When removing the lock (6) mounted on the cylinder head, be careful as it is very fragile.
- When unscrewing the union nut (1. fig. 4.59) fastening the fuel injection pipe to the injector body, it is necessary to hold the nut with a second wrench (2) filter mounting. Plug the holes with plugs.
- Unscrew the bolts (5, fig. 4.58) fuel rail mountings and rail mounting flange bolt on the lower sheet metal guard, and then remove the rail with side baffle.
- Disconnect the diesel fuel return pipe (1. fig. 4.64).
Pic. 4.64. Tube location (1) return of diesel fuel and side bulkhead bolts (2) and lower protective element made of sheet metal (3)
- Remove the bolt (2) fastening the side partition.
- Remove the bolt (3) fastening the lower sheet metal protective element.
- Remove the line protection with the side partition, and then remove the center partition partition.
- Detach the rubber apron from the lower sheet metal guard.
Installation
- Install the rubber apron onto the lower sheet metal guard using the five rubber clips (1. fig. 4.65). Make sure the rubber clips are securely installed
Pic. 4.65. Location of rubber clamps (1)
- Install the rubber apron assembly/lower sheet metal guard assembly to the engine.
- Install the side partition to the bottom sheet metal guard, being sure to follow the following procedure:
- fasten the bottom loop (1. fig. 4.66); - place the rounded rubber part of the partition onto the lower sheet metal protective element;
- place the upper part of the partition on the sheet metal protective element;
- fasten the top loop (1, fig. 4.67);
- screw in the bolt (2) partition fastenings;
- connect the diesel fuel drain pipe (3). making sure it is not clogged.
Pic. 4.66. Bottom hinge installation location (1) and the rounded rubber part of the partition (2)
Pic. 4.67. Top hinge installation location (1), bolt (2) fastening the partition and drain pipe (3) diesel fuel
- Install the fuel distribution line with the baffle without tightening the line mounting bolts.
- Remove the plugs from the line, injector bodies, pump and fuel injection lines.
- Connect the fuel injector lines between the line and the injectors, first tightening the connections between them by hand until they touch.
- Torque:
- 23 Nm three mounting bolts for fastening the line;
- 25 Nm fittings of the fuel injection lines at the injectors and at the high pressure pump;
- 25 Nm fittings of the fuel injection lines at the line.
- Install absorbent foam pads, replacing them if they are damaged or saturated with diesel fuel.
- Install the sealing partition in place, securing it with two nuts on the cylinder head cover.
- Make sure the label is installed correctly (1. Fig 4.68) highway partitions (along the axis of the high pressure fuel outlet lines)
Pic. 4.68. Label location (1) highway partitions
- Connect the connectors to the injectors and the line pressure sensor.
- Install the new diesel fuel return line, making sure that the mounting clamps are in place, at the level of the injectors and at the end of the line, at the level of the overpressure valve
- Move the rubber apron forward and attach the side sealing partitions to it.
- Make sure that the partitions are securely fastened with clamps, as well as that the skirts of the rubber apron are correctly positioned
- Attach the rubber apron to the cylinder head cover and engine mount. Make sure that the apron is securely fastened with clamps to the cylinder head cover and engine support.
- Using a diagnostic tool, check for any fault codes recorded in the memory and, if present, delete them; make sure that the diesel fuel return pipe is securely connected.
- After carrying out any work, check that there are no leaks from the diesel fuel supply circuit. Let the engine idle until the electric cooling fan turns on, then increase the engine speed several times while idling. Do a road test. Turn off the ignition and check the vehicle for diesel leaks. Check that the porous gaskets are not saturated with diesel fuel.