| Removal and Installation Special Tool(s) | | Hand Pressure Pump with Adapter Kit 310-110 | General Equipment WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1600 bar. Failure to follow this instruction may result in personal injury. WARNING:Wait at least one minute after the engine stops before commencing any repair to the fuel injection system. Failure to follow this instruction may result in personal injury. CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. CAUTION:Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors when required. CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components to prevent foreign matter ingress to the components. | | -
Remove the turbocharger intake pipe support bracket retaining bolt. | 4. Remove the components in the order indicated in the following illustration(s) and table(s). 3 - Turbocharger vacuum control pipe and fuel pump fuel return line retaining clip 4 - Fuel pump fuel temperature sensor electrical connector 5 - Fuel pump fuel pressure regulator electrical connector 8 - Fuel injection supply manifold high pressure fuel supply line support bracket 5. To install, reverse the removal procedure. | | -
Do not install the engine upper cover at this stage. | CAUTION:The generator must be protected from contamination. Failure to follow this instruction may cause premature failure of the generator. | | -
Protect the generator with lint-free material to prevent contamination. | | | -
NOTE:Make sure the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Install the special tool between the fuel tank fuel supply line quick release coupling and the fuel filter union. | | | -
Operate the hand pressure pump at least 30 times. | | | -
Remove the lint-free material. | | | -
CAUTION:Do not operate the starter motor for longer than 10 seconds at a time. After 10 seconds, turn the ignition to position 0 and allow the starter motor to cool for 30 seconds before attempting to start the engine again. Start the engine and allow it to idle until it reaches normal operating temperature. | | | -
Protect the generator with lint-free material to prevent contamination. | | | -
Remove the hand pressure pump. | | | -
Remove the lint-free material. | | | -
Install the engine upper cover. | Removal Details Item 1 : Positive crankcase ventilation (PCV) oil return hose | | -
Remove the PCV oil return hose. - Disconnect the PCV oil return hose from the oil filler tube.
- Disconnect the PCV oil return hose from the intake manifold PCV valve and remove.
| Item 2 : Brake booster vacuum pipe to vacuum pump quick release connector Item 6 : Fuel pump fuel supply line quick release coupling
Item 7 : Fuel pump fuel return line quick release coupling | | -
Install new blanking plugs to the open ends of the fuel pump fuel supply and fuel return lines and fuel pump unions. | Item 9 : Fuel injection supply manifold high pressure fuel supply line CAUTION:Make sure that the high-pressure fuel supply line remains in contact with both the fuel pump and the fuel injection supply manifold until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system. | | -
Clean the fuel pump, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas. For additional information, refer to Fuel Injection Component Cleaning in this section. | | | -
Detach the high-pressure fuel supply line unions from the fuel pump and the fuel injection supply manifold. | | | -
Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold. | | | -
Remove and discard the high-pressure fuel supply line. | | | -
Install new blanking plugs to the open threaded ports on the fuel pump and the fuel injection supply manifold. | Installation Details Item 9 : Fuel injection supply manifold high pressure fuel supply line CAUTION:Remove the blanking plugs from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold at the last possible moment. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system. CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system. CAUTION:Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions. NOTE: Maintain pressure on the high-pressure fuel supply line to keep the line in contact with the fuel injector cone and fuel injection supply manifold while installing the unions. NOTE:If it is not possible to correctly install the new high-pressure fuel supply line, it will be necessary to remove the remaining high-pressure fuel supply lines and to loosen the fuel injection supply manifold to allow correct alignment. | | -
Using the pneumatic vacuum gun, vacuum foreign material from the area around the fuel pump and the fuel injection supply manifold. | | | -
Remove and discard the blanking plugs from the high-pressure fuel supply line, the fuel injection supply manifold and the fuel pump. | | | -
Install the fuel injection supply manifold high-pressure fuel supply line. - Hand tighten the high-pressure fuel supply line unions.
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Tighten the fuel injection supply manifold high-pressure fuel supply line unions. | Item 7 : Fuel pump fuel return line quick release coupling
Item 6 : Fuel pump fuel supply line quick release coupling | | -
Remove and discard the blanking plugs. | |
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