Fuel Return Block Replacement

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the air cleaner outlet duct.
4. Remove the right turbo charged air outlet hose.




5. Remove the left turbo charged air outlet hose.
6. Remove the engine wiring harness.




7. Remove the heater pipe assembly.




8. Remove the fuel feed line (1).
9. Remove the generator.




10. Remove the fuel hoses from fuel feed block (1).
11. Remove the fuel feed block bolt and nut and remove feed block (1).
12. Remove the fuel leak-off block pipe to cylinder head bolt.
13. Remove the fuel leaf-off block (2).

INSTALLATION PROCEDURE

IMPORTANT: Always install new fuel line gaskets when servicing fuel lines.




1. Install the fuel leaf-off block (2).

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel leak-off block pipe to cylinder head bolt.

Tighten
Tighten the leak-off block pipe bolt to 15 N.m (11 lb ft).

3. Install the fuel feed block (1) and bolt and nut.

Tighten
Tighten the nut and bolt to 25 N.m (18 lb ft).

4. Install the fuel hoses to fuel feed block (1).
5. Install the generator.




6. Install the fuel feed line (1).

Tighten
Tighten the fuel feed line to 8 N.m (70 lb in).




7. Install the heater pipe assembly.

Tighten
Tighten the heater pipe bolt to 20 N.m (14 lb ft).




8. Install the engine wiring harness assembly.
9. Install the left turbo charged air outlet hose.




10. Install the right turbo charged air outlet hose.
11. Install the air cleaner outlet duct.
12. Connect the negative battery cable.
13. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.