Fuel Return Pipe Replacement

REMOVAL PROCEDURE




1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) Starting and Charging.
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 fuel feed line (1).




8. Remove the fuel injection pump to fuel feed block hose.




9. Remove the glow plug controller.




10. Remove the bolts from cylinder head (2), leak-off block and junction block.




11. Remove the fuel line retainers.




12. Remove the fuel return line assembly.

INSTALLATION PROCEDURE

NOTE: Refer to Fastener Notice in Service Precautions.

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




1. Install the fuel return line assembly.

Tighten
Tighten the bolt to 27 N.m (19 lb ft).




2. Install the fuel line retainers.

Tighten
Tighten the bolt to 16 N.m (11 lb ft).




3. Install the bolts to the cylinder head (2), leak-off block and junction block.

Tighten
Tighten the bolts to 15 N.m (11 lb ft).




4. Install the glow plug controller.




5. Install the fuel injection pump to fuel feed block hose.




6. Install the fuel feed line (1).

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




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




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