| 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 (414-01, General Procedures).
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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. - Detach the cowl panel from the retaining clips.
- Remove the cowl panel by detaching it from the windshield glass lower weatherstrip.
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Remove the bulkhead extension panel. - Remove the bulkhead extension panel retaining screws.
- Detach the bulkhead extension panel from the retaining clips.
| 7. Remove the components in the order indicated in the following illustration(s) and table(s). 2 - Fuel injector wiring harness support retaining bolts 3 - Fuel injector electrical connectors 4 - Water-in-fuel sensor electrical connector 5 - Fuel heater electrical connector 6 - Fuel rail pressure sensor electrical connector 7 - Exhaust gas recirculation (EGR) valve electrical connector 8 - Fuel temperature sensor electrical connector 14 - Fuel filter fuel supply line and fuel pump fuel return line retaining clip See Removal Detail 20 - Fuel injection system fuel supply and return lines 22 - Glow plug wire support bracket 23 - Glow plug wire retaining nuts 8. To install, reverse the removal procedure. | | -
Vehicles with global closing, initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11, General Procedures).
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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 filter fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
| Removal Details Item 10 : EGR valve tube retaining clamp | | -
Make a note of the position of the EGR tube retaining clamp before removal. | Item 12 : Fuel tank to fuel filter fuel supply line quick release coupling | | -
Clean the fuel injector, fuel rail, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04D, General Procedures).
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Detach the fuel filter fuel supply line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
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Install blanking plugs to the open ends of the fuel supply line and fuel filter fuel supply line. | Item 13 : Fuel pump fuel return line quick release coupling | | -
Clean the fuel injector, fuel rail, high-pressure fuel supply line and surrounding areas.
For additional information, refer to: Fuel Injection Component Cleaning (303-04D, General Procedures).
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Detach the fuel pump fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
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Install blanking plugs to the open ends of the fuel pump and fuel pump fuel return line. | Item 14 : Fuel filter fuel supply line and fuel pump fuel return line 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 line connections | | -
Detach the fuel injector fuel return line from the fuel injector. - Remove the fuel injector fuel return line retaining clip.
- Detach the fuel injector fuel return line.
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Install blanking plugs to the open ends of the fuel injector fuel return lines and the fuel injectors. | Item 21 : Glow plug wire electrical connector | | -
Disconnect the glow plug wire electrical connector and detach the glow plug wire electrical connector from the retaining bracket. | Installation Details Item 15 : Fuel injector fuel return line connections | | -
Remove and discard the blanking plugs from the fuel injectors and the fuel injector return line connections. | Item 13 : Fuel pump fuel return line quick release coupling | | -
Remove and discard the blanking plugs from the fuel pump fuel return line quick release connectors and fuel pump. | | | -
Connect the fuel pump fuel return line quick release coupling.
For additional information, refer to: Quick Release Coupling (310-00, General Procedures).
| Item 12 : Fuel tank to fuel filter fuel supply line quick release coupling | | -
Remove and discard the blanking plugs. | | | -
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 to fuel filter fuel supply line quick release coupling and the fuel filter fuel supply line. | Item 10 : EGR valve tube retaining clamp | | -
NOTE:Do not tighten the EGR valve tube retaining bolts at this stage. Install the EGR valve tube retaining bolts. | | | -
NOTE:A new EGR valve tube retaining clamp must be installed in the same position as removed. Install a new EGR valve tube retaining clamp. | Item 9 : EGR valve tube retaining bolts | | -
Tighten the EGR valve tube to intake manifold retaining bolts. | | | -
Tighten the EGR valve tube to engine retaining bolt. | |
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