Attention.
- Leaks in fuel lines in a pressurized system are dangerous. Fuel can ignite and cause equipment damage, serious injury, or even death. Fuel can also come into contact with human skin and eyes. To prevent this, it is essential to perform a pressure relief procedure in the fuel system.
- A person carrying a static charge can cause a fire or explosion, which could result in death or serious injury. Before working on the fuel system, you must discharge static electricity by touching the vehicle body.
- If fuel gets on engine parts, it may cause damage to those components or cause a fire. Be sure to wipe up any spilled fuel with a clean rag.
- Prevent foreign materials from entering the high-pressure fuel line. To do this, be sure to tighten the high-pressure fuel line connections to the specified tightening torque.
Removal high pressure fuel lines
1. Disconnect the negative battery terminal.
2. Perform the procedure for preparing for servicing the power supply system.
3. Remove the decorative engine cover.
4. Unscrew the connecting nuts and remove the high-pressure fuel lines from the injector side.
1. High pressure fuel lines from the fuel injector side.
2. High pressure fuel line from the fuel pump side.
Note.: replace the part with a new one after each removal.
5. Remove the return fuel line from the fuel pump side.
6. Remove the high pressure fuel line from the fuel pump side.
Installation of high pressure fuel lines
1. Loosen the Common Rail fuel rail.
2. Tighten the connecting nuts of the new high-pressure fuel line on the high-pressure fuel pump side.
3. Tighten the connecting nuts of the high-pressure fuel lines on the fuel injector side.
4. Fit the return fuel line on the high pressure fuel pump side.
5. Tighten the new clamp to a torque of 4.2-5.2 Nm.
6. Tighten the high-pressure fuel line bracket on the high-pressure fuel pump side to 8-11 Nm.
7. Tighten the nuts of all high-pressure fuel lines on the Common Rail fuel rail side to a torque of 32-42 Nm.
8. Tighten the high-pressure fuel lines on the fuel pump and fuel injector side to a torque of 32-42 Nm.
9. Tighten the fuel rail to a torque of 20-26 Nm.
10. Tighten the fuel return line:
- From the high pressure fuel pump side with a torque of 18-26 Nm.
- From the lower housing side with a torque of 20-26 Nm.
11. Perform the procedure for removing air from the fuel lines.