Removal
All cars
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.
Wait at least one minute after stopping the engine before attempting any repairs to the fuel injection system. Failure to follow these instructions may result in injury.
CAUTION: Diesel injection equipment is manufactured to very precise tolerances and with very small clearances. It is therefore especially important to maintain absolute cleanliness when working with these components. Open holes or lines should always be plugged using suitable plugs.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.
2. Remove the top engine cover.
3. Remove the air deflector.
4. Disconnect the charge air cooler inlet pipe.
Cars with diesel engine 100 hp.
5. Disconnect the charge air cooler outlet pipe. Disconnect the vacuum line from the charge air cooler outlet pipe.
Cars with 115 hp diesel engine.
6. Disconnect the charge air cooler outlet pipe.
All cars
7. Disconnect the intake air temperature (IAT) sensor connector and remove the charge air cooler and lines.
8.
CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.
Cover the generator with a lint-free material to prevent contamination.
9. Disconnect the plug connectors of the fuel metering valve and the fuel temperature sensor (for clarity, the high-pressure fuel supply line is shown removed).
10. Remove the fuel pump support bracket bolts (for clarity, the high-pressure fuel supply line is shown removed).
11. Disconnect the fuel return line from the fuel pump to the fuel filter from the fuel return line diffuser (the high pressure fuel supply line is shown removed for clarity). Refer to Section 310-00 for additional information.
- Install plugs on the fuel pump return fuel line and the fuel return line diffuser.
12. Disconnect the fuel injector return fuel line from the fuel return line diffuser.
- Install the plugs on the fuel injector return line and the fuel return line diffuser.
13. Remove the screen from the fuel pump (for clarity, the fuel pump is shown removed).
14. Clean the fuel pump, fuel pump return lines and surrounding area. For more information, refer to the Cleaning Fuel Injection System Components chapter in this section.
15. Using an air vacuum gun, remove foreign material from the fuel pump, fuel return line diffuser and fuel pump return lines.
16. Remove the fuel return line diffuser (the fuel pump is shown removed for clarity). Install a plug in the open port of the fuel pump.
Installation
All cars
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.
CAUTION: Diesel injection equipment is manufactured to very precise tolerances and with very small clearances. It is therefore especially important to maintain absolute cleanliness when working with these components. Open holes or lines should always be plugged using suitable plugs.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
1.
CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.
Cover the generator with a lint-free material to prevent contamination.
2. Install the return fuel line diffuser (the fuel pump is shown removed for clarity). Discard the plugs as they are no longer needed.
3. Install the screen on the fuel pump (for clarity, the fuel pump is shown removed).
4. Remove the plugs and connect the fuel injector return line to the fuel return line diffuser. Discard the plugs as they are no longer needed.
5. Connect the plug connectors of the fuel metering valve and the fuel temperature sensor (for clarity, the high-pressure fuel supply line is shown removed).
6. Tighten the fuel pump support bracket bolts (the high pressure fuel supply line is shown removed for clarity).
7. Connect the fuel return line from the fuel pump to the fuel filter.
8. Remove the lint-free material from the generator.
9. Install the charge air cooler and lines and connect the IAT sensor plug.
Cars with 115 hp diesel engine.
10.
CAUTION: Make sure the inside of the end of the charge air cooler outlet pipe is clean and free of oil, as this will reduce adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the charge air cooler outlet pipe.
Cars with diesel engine 100 hp.
11.
CAUTION: Make sure the inside of the charge air cooler outlet pipe end is clean and free of oil, as this will reduce adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the outlet pipe to the charge air cooler.
- Connect the vacuum line to the charge air cooler outlet pipe.
All cars
12.
CAUTION: Make sure that the inside of the charge air cooler intake pipe is clean and free of oil, as this will impair the bond between the pipe and the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the charge air cooler inlet pipe.
13. Install the air deflector.
14. Install the top engine cover.
15. Connect the ground cable to the battery. For additional information, refer to Section 414-01.
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