Removal and installation of the high pressure fuel line between the fuel pump and the rail
Removing the high pressure fuel line
1. Disconnect the negative battery terminal.
2. Remove the turbocharger air duct.
3. Remove the oil dipstick.
4. Loosen the screws (1) and remove the oil dipstick guide to the side.
5. Unhook the latches (2) fuel rail covers.
6. Loosen the bolt (3) and remove the protective cover of the fuel rail.
7. Disconnect connector (4) fuel rail pressure sensor.
8. Disconnect the fuel temperature sensor connector (5).
9. Disconnect connector (6) flow control solenoid valve.
10. Disconnect the connectors of all glow plugs.
11. Disconnect all fuel injector connectors.
12. Unhook the clips (7) injection control wires.
13. Loosen the nut (8) from the injection control wiring bracket.
14. Remove wiring to the side
15. Loosen the nuts (9) and remove the fuel rail guard.
16. Clean the high pressure fuel line connectors between the fuel pump and rail.
Caution: To prevent corrosion or damage, care must be taken to protect surfaces that may be exposed to escaping fuel.
17. Loosen the nuts (10) fuel rail.
Caution: When loosening the high pressure fuel lines, be sure to hold the intermediate connection with a wrench. Be careful not to damage the return line of the fuel injectors.
18.Remove the high pressure fuel line (11) between the high pressure fuel pump and the fuel rail.
19. Place suitable plugs on the ports of the high pressure fuel pump and fuel rail.
High pressure fuel line installation
Attention:
- Before installing a new high pressure fuel line, lightly lubricate the threads of the nut with oil from the tube supplied in the new repair kit.
- Be careful not to get oil into the fuel line.
- Do not lubricate the high pressure fuel lines supplied without a tube - these fuel lines are already lubricated.
Attention:
- You must remove the plugs from the components and remove the components from the packaging immediately before installing the component.
- Be sure to replace the high pressure fuel line between the fuel pump and the rail with a new one after each removal.
1. Remove the plugs from the high pressure fuel pump and fuel rail ports.
2. Install a new high pressure fuel line between the fuel rail and the high pressure fuel pump.
3. Loosely tighten the high pressure fuel line nuts between the fuel rail and the high pressure fuel pump by hand, starting at the fuel rail side.
4. Using a special wrench for tightening the connecting nuts of the fuel lines, tighten the nuts of the high pressure fuel line between the fuel rail and the high pressure fuel pump to a torque of 28 Nm.
5. Tighten the fuel rail mounting nuts to 28 Nm.
6. Install fuel rail protection.
7. Install injection control wiring.
8. Install the injection control wiring bracket nut.
9. Hook up the wiring clamps.
10. Connect the connectors of all fuel injectors.
11. Connect the connectors of all glow plugs.
12. Connect the fuel control solenoid valve connector.
13. Connect the fuel temperature sensor connector.
14. Connect the fuel rail pressure sensor connector.
15. Install the protective cover of the fuel rail and tighten the bolt of its fastening.
16. Hook the protective cover of the fuel rail.
17. Install the dipstick guide tube and tighten the fixing bolts.
18. Install the oil dipstick.
19. Install the turbocharger outlet duct.
20. Connect the battery.
21. Fill the system with fuel using the manual priming pump (with automatic venting).
22. Check for fuel leaks.
Removal and installation of high pressure fuel lines between the fuel rail and injectors
Removing high pressure fuel lines between fuel rail and injectors
1. Disconnect the negative battery terminal.
2. Remove the engine cover.
3. Remove the turbocharger air duct.
4. Remove the oil dipstick.
5. Loosen the bolts (1) and remove the oil dipstick guide to the side.
6. Unhook the latches (2) fuel rail cover.
7. Clean the high pressure fuel line connectors between the fuel rail and injectors.
Attention:
- When loosening the high pressure fuel lines, be sure to hold the intermediate connection with a wrench. Be careful not to damage the return line of the fuel injectors.
- Measures must be taken to protect surfaces that may be exposed to escaping fuel to prevent corrosion or damage.
If it is necessary to remove single high pressure fuel lines
8. With special tool (Mot. 1566) loosen the union nuts of the high pressure fuel lines between the fuel rail and the injectors.
9. Unscrew the connecting nuts of the high pressure fuel lines between the fuel rail and the injectors from the side of the fuel rail.
10. Unscrew the connecting nuts of the high pressure fuel lines between the fuel rail and the injectors on the injector side.
11. Remove the high pressure fuel line.
12. Install the appropriate plugs on the fuel rail and injector ports.
If it is necessary to remove the high pressure fuel lines in one package
13. Disconnect connector (4) fuel rail pressure sensor.
14. Disconnect the fuel temperature sensor connector (5).
15. Disconnect connector (6) flow control solenoid valve.
16. Disconnect the connectors of all glow plugs.
17. Disconnect all fuel injector connectors.
18. Unhook the clips (7) injection control wiring.
19. Loosen the nut (8) from the injection control wiring bracket.
20. Remove wiring to the side.
21. Loosen the nuts (9) and remove the fuel rail guard.
22. Loosen the nuts (10) fuel rail.
23.Using a special tool (Mot. 1566) loosen the union nuts of the high pressure fuel lines between the fuel rail and the injectors.
24. Loosen the connecting nuts of the high pressure fuel lines between the fuel rail and the injectors on the side of the fuel rail.
25. Unscrew the connecting nuts of the high pressure fuel lines between the fuel rail and the injectors on the injector side.
26.Remove the high pressure fuel lines.
27. Install the appropriate plugs on the fuel rail and injector ports.
Installation of high pressure fuel lines between the fuel rail and injectors
Attention:
- Before installing a new high pressure fuel line, lightly lubricate the threads of the nut with oil from the tube supplied in the new repair kit.
- Be careful not to get oil into the fuel line.
- Do not lubricate the high pressure fuel lines supplied without a tube - these fuel lines are already lubricated.
Attention:
- You must remove the plugs from the components and remove the components from the packaging immediately before installing the component.
- Be sure to replace the high pressure fuel lines between the fuel rail and the injectors with new ones after each removal.
1. Remove plugs from fuel rail ports and injectors.
2. Install new high pressure fuel lines between fuel rail and injectors.
3. Loosely tighten the high pressure fuel line nuts between the fuel rail and the high pressure fuel pump by hand, starting at the fuel rail side.
4. Using a special wrench for tightening the connecting nuts of the fuel lines, tighten the nuts of the high pressure fuel line between the fuel rail and the injectors to a torque of 28 Nm.
5. Tighten the fuel rail mounting nuts to 28 Nm.
6. Install fuel rail protection.
7. Install injection control wiring.
8. Install the injection control wiring bracket nut.
9. Hook up the wiring clamps.
10. Connect the connectors of all fuel injectors.
11. Connect the connectors of all glow plugs.
12. Connect the fuel control solenoid valve connector.
13. Connect the fuel temperature sensor connector.
14. Connect the fuel rail pressure sensor connector.
15. Install the protective cover of the fuel rail and tighten the bolt of its fastening.
16. Hook the protective cover of the fuel rail.
17. Install the dipstick guide tube and tighten the fixing bolts.
18. Install the oil dipstick.
19. Install the turbocharger outlet duct.
20. Connect the battery.
21. Fill the system with fuel using the manual priming pump (with automatic venting).
22. Check for fuel leaks.