Contents: Removal procedure ↧ Installation procedure ↧
Removal procedure
Caution! Do not smoke or use open flames in areas where work is being performed on the fuel system. When working on the fuel system, disconnect the negative battery cable except for those checks that require battery voltage.
1. Remove the decorative cover. See Section 1B, "Engine Mechanical System - 2.0 Diesel".
2. Remove the supercharged air system. See Section 1B, "Engine Mechanical System - 2.0 Diesel".
3. While holding the injector coupling (a), unscrew the nut (M14) securing the fuel line to the injector.
Caution! To avoid fuel spillage or damage from the injector coupling, hold the injector coupling with tools and unscrew the tube nut. And then, immediately after removing the fuel lines, put the cap on the injector connector to avoid contamination with dust. Even a small amount of dust can clog the injectors.
4. Holding the injection pump coupling (a), unscrew the nut (M14) securing the fuel line to the common fuel rail.
Caution! To avoid fuel spillage or damage from the injection pump coupling, hold the injection pump coupling with tools and unscrew the nut (M14) securing the fuel line to the common fuel rail. And then, immediately after removing the fuel lines, put the cap on the injection pipe connector to prevent contamination with dust. Even a small amount of dust can clog the injectors.
5. Unscrew the nut securing the fuel line to the common fuel rail (M17).
6. Remove the bolt securing the fuel line to the common fuel rail from the thermostat housing.
7. Remove the tube from the fuel line to the common fuel rail and the tubes from the fuel line to the injectors.
Caution! Immediately after removing the threaded connections, put caps on the threaded connections of the pipes of the common fuel rail to avoid contamination with dust. Even a small amount of dust can clog the injectors.
Installation procedure
Important: Fuel lines cannot be reused. Reusing contaminated lines may cause damage to injectors or leaking lines.
Caution! Fuel lines cannot be reused. Reusing contaminated lines may cause damage to injectors or leaking lines.
Caution! Do not wipe with napkins inside the injector couplings, injection pump and threaded connections of the pipes of the common fuel rail. If dirty, wipe the dusty area with oiled paper.
1. If the threaded connection of the common fuel rail tube is dirty, clean it with oiled paper.
2. Loosen the injector bracket bolts. See "Nozzle" in this section.
3. Install the fuel lines between the injectors and the common rail and hand tighten the nuts.
Caution! Do not tighten the fuel line nuts with a tool.
4. Tighten the injector bracket bolts.
Tighten
Tighten the injector bracket bolt to 28 Nm (20.7 ft·lbs).
5. While holding the injector coupling (a), tighten the nut (M14) securing the fuel line to the injector.
Tighten
Tighten the nut (M14) securing the fuel line to the injector to 27 Nm (19.9 ft·lbs).
6. Tighten the nut (M17) securing the fuel line to the injector.
Tighten
Tighten the nut (M17) securing the fuel line to the injector to 20 Nm (14.8 ft·lbs).
7. Install the fuel line between the common rail and the injection pump and hand tighten the nuts.
Caution! Do not tighten the fuel line nuts with a tool.
8. While holding the injection pump coupling (a), tighten the nut (M14) securing the fuel line to the common fuel rail.
Tighten
Tighten the nut (M14) securing the fuel line to the common fuel rail to 20 Nm (14.8 ft·lbs).
9. Tighten the nut (M17) securing the fuel line to the common fuel rail.
Tighten
Tighten the nut (M17) securing the fuel line to the common fuel rail to 20 Nm (14.8 ft·lbs).
(The original article can be found on the resource «chevyman»)