| 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. 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: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. | | -
NOTE:Make sure that the windshield wiper motor is in the park position. Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect.
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Remove the engine upper cover. | | | -
Detach the brake fluid reservoir from the bulkhead extension panel. | | | -
Remove the windshield wiper arms. | | | -
Remove the cowl panel grille. - Detach the cowl panel grille retaining clips.
- Detach the cowl panel grille from the windshield glass lower weatherstrip and remove.
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Remove the bulkhead extension panel. | 7. Remove the components in the order indicated in the following illustration(s) and table(s). 2 - Fuel injector harness trunking retaining bolts 3 - Fuel injector electrical connectors 4 - Water in fuel sensor electrical connector 5 - Fuel heater electrical connector 6 - Fuel injection supply manifold pressure sensor electrical connector 7 - Exhaust gas recirculation (EGR) valve electrical connector 8 - Fuel temperature sensor electrical connector 14 - Fuel filter fuel supply pipe and fuel pump fuel return pipe retaining clip See Removal Detail 20 - Fuel injection system fuel supply and return pipes 22 - Glow plug wire support bracket 23 - Glow plug wire retaining nuts 8. To install, reverse the removal procedure. | | -
Using the special tool, prime the fuel system. - Operate the hand pump until it becomes firm when squeezed.
- Squeeze and hold the hand pump for 10 seconds.
- Squeeze and hold the hand pump for a further 10 seconds.
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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 to idle until it reaches normal operating temperature. | | | -
Remove the hand pressure pump and connect the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling.
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Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization.
| Removal Details Item 10 : EGR tube retaining clamp | | -
Make a note of the position of the EGR tube retaining clamp before removal. | Item 12 : Fuel supply line quick release coupling | | -
Clean the fuel injector, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning.
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Detach the fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling.
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Install blanking plugs to the open ends of the fuel supply line and fuel filter fuel supply pipe. | Item 13 : Fuel pipe quick release coupling
Item 16 : Fuel pipe quick release coupling
Item 17 : Fuel pipe quick release coupling
Item 18 : Fuel pipe quick release coupling
Item 19 : Fuel pipe quick release coupling | | -
Clean the fuel injector, fuel injection supply manifold, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning.
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Detach the quick release couplings.
For additional information, refer to: Quick Release Coupling.
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Install blanking plugs to the open ends of the detached fuel pipe and fuel component. | Item 14 : Fuel filter fuel supply pipe and fuel pump fuel return pipe retaining clip | | -
Detach the fuel filter fuel supply line and fuel pump fuel return line from the intake manifold. | Item 15 : Fuel Injector fuel return pipe connections | | -
Detach the fuel return pipe from the fuel injector. - Remove the fuel return pipe retaining clip.
- Detach the fuel return pipe.
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Install blanking plugs to the open ends of the fuel return pipes and the fuel injectors. | Item 21 : Glow plug wire electrical connector | | -
Disconnect the glow plug loom electrical connector and detach the glow plug wire electrical connector from the retaining bracket. | Installation Details Item 19 : Fuel pipe quick release coupling
Item 18 : Fuel pipe quick release coupling
Item 17 : Fuel pipe quick release coupling
Item 16 : Fuel pipe quick release coupling
Item 13 : Fuel pipe quick release coupling | | -
Remove and discard the blanking plugs from the fuel pipe quick release connectors and fuel components. | | | -
Connect the fuel line quick release coupling.
For additional information, refer to: Quick Release Coupling.
| Item 15 : Fuel Injector fuel return pipe connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return pipe connections. | Item 12 : Fuel supply line quick release coupling | | -
NOTE:Make sure the hand pressure pump arrow indicating the direction of fuel flow is pointing towards the fuel filter. Remove and discard the blanking plugs. Install the special tool between the fuel tank fuel supply line quick release coupling and the fuel injection fuel supply pipe union. | Item 10 : EGR tube retaining clamp | | -
Install the EGR tube retaining bolts finger tight. | | | -
Install a new EGR tube retaining clamp in the same position as when removed. | Item 9 : EGR tube retaining bolts | | -
Tighten the EGR tube to intake manifold retaining bolts. | | | -
Tighten the EGR tube to engine retaining bolt. | | 
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