Attention! Do not smoke or use open flames in areas where work is being done on the fuel system. When working on the fuel system, disconnect the negative battery cable, except for tests that require battery voltage.
Removal procedure
1. Disconnect the negative battery cable.
2. Disconnect the common rail pressure sensor connector.
3. Disconnect the common rail regulator connector.
4. Disconnect the common rail return hose.
5. Remove the engine wire guide from the intake manifold.
6. Remove the high pressure fuel lines. See «High pressure fuel supply lines» in this section.
7. Remove the common fuel rail assembly.
Attention! Immediately after removing the fuel lines, put a cap on the threaded connections of the common rail pipes to prevent dust contamination. Even small amounts of dust can clog nozzles.
Installation procedure
Important: Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Do not blow air from the spray gun inside the injector sleeves, the injection pump and the threaded connections of the pipes of the common fuel rail. In case of contamination, wipe the dusty area with oiled paper.
Attention! Do not wipe with napkins inside the injector couplings, injection pump and threaded connections of the pipes of the common fuel rail. In case of contamination, wipe the dusty area with oiled paper.
1. Install the common fuel rail assembly.
Tighten
Tighten the common rail mounting bolts to 25 Nm (18.4 lb-in).
2. Install the fuel lines to the common fuel rail. See «High pressure fuel supply lines» in this section.
3. Connect the common rail pressure sensor connector.
4. Connect the common rail regulator connector.
5. Perform fuel bleeding. See «Fuel pumping» in this section.