Special tool
 | World Diagnostic System (WDS) 418-F224 |
General equipment: Pneumatic vacuum gun.
| Name | Specification |
| Lubricant for the nipple connection of the TBD high pressure fuel supply line | TBD |
Withdrawal
All cars
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure is related to fuel handling. Always be aware of the possibility of fuel splashing and observe fuel handling precautions. Failure to follow these instructions may result in injury.
WARNING: Do not make any repairs to the fuel injection system while the engine is running. The fuel pressure in the system can reach 1600 bar. Failure to follow these instructions may result in injury.
WARNING: Do not make any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or below 30°C, whichever is greater. Failure to follow these instructions may result in injury.
WARNING: After stopping the engine, wait at least one minute before making any repairs to the fuel injection system. Failure to follow these instructions may result in injury.
WARNING: Make sure that the workshop area where the vehicle is being worked on is as clean and dust free as possible. Foreign matter from work on the clutch, brakes, or machining or welding operations can contaminate the fuel system and result in subsequent malfunction.
CAUTION: Always perform the cleaning procedure before making any repairs to the fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Open holes or lines should always be plugged with appropriate plugs.
CAUTION: Do not disassemble fuel injectors or clean their nozzles, even with ultrasonication. Always install new fuel injectors if necessary.
1. Using the function «Data logger» («Datalogger») world diagnostic system (WDS), check that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or a temperature below 30°C, whichever is greater.
2. Disconnect a wire of weight from the accumulator. See Section 414-01 for more information.
3. Remove the engine top cover.
4. Remove the air baffle.
5. Disconnect the charge air cooler inlet pipe.
Vehicles with a 100 HP diesel engine
6. Disconnect the charge air cooler outlet pipe. Disconnect the vacuum line from the charge air cooler outlet pipe.
Vehicles with a 115 hp diesel engine
7. Disconnect the charge air cooler outlet pipe.
All cars
8. Disconnect the plug connector of the air intake temperature sensor (IAT) and remove the charge air cooler and piping.
9. Disconnect the fuel pressure sensor connector and cover the connector with a lint-free cloth to prevent it from being contaminated by the cleaning fluid.
10.
CAUTION: Protect generator from contamination. Failure to follow this instruction may result in premature generator failure.
Cover the generator with lint-free material to prevent contamination.
11.
CAUTION: Cover fuel injector plugs with lint-free material to prevent contamination with cleaning fluid.
Clean fuel injectors, fuel manifold, high pressure fuel supply lines and adjacent areas. For more information, refer to the chapter Cleaning the fuel injection system components found in this section.
12. Remove the high pressure fuel line bracket.
13. Clean the fuel pump, fuel manifold, high pressure fuel supply line and adjacent areas. For more information, refer to the chapter Cleaning the fuel injection system components found in this section.
14.
CAUTION: The high pressure fuel supply line must remain in contact with the fuel pump and fuel manifold until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Disconnect the high pressure fuel supply line and clamp from the fuel pump and fuel manifold.
15.
CAUTION: The high pressure fuel supply line must remain in contact with the fuel pump and fuel manifold until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Using a pneumatic vacuum gun, remove foreign material from the high pressure fuel supply line, fuel pump and fuel manifold.
16. Remove the high pressure fuel supply line and discard it as no longer needed.
17. Using a pneumatic vacuum gun, remove foreign material from the fuel pump and fuel manifold.
18. Install the plugs in the open threaded holes on the fuel pump and fuel manifold.
19.
NOTE: Mark the orientation of the clip to ensure it is installed in exactly the same position.
Remove the clamp from the high pressure fuel supply line.
20. Discard the high pressure fuel supply line as it is no longer needed.
21.
NOTE: Mark the orientation of the clips to ensure they are installed in exactly the same position.
Remove the high pressure fuel supply line clamps.
22.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel injectors until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Disconnect the high pressure fuel lines from the fuel injectors (for clarity, forced crankcase ventilation hoses (PCV) shown removed).
23.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel manifold until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Disconnect the high pressure fuel lines.
24.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel injectors until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Using a pneumatic vacuum gun, remove foreign material from the high pressure fuel supply lines and fuel manifold.
25. Remove the high pressure fuel feed lines and discard them as no longer needed.
26. Using a pneumatic vacuum gun, remove foreign material from the fuel injectors and fuel manifold.
27. Install plugs in the exposed threaded holes of the fuel injectors and fuel manifold.
28. Remove the fuel manifold.
Installation
All cars
WARNING: Do not smoke or allow a lit cigarette or open flame of any kind to be present when working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure is related to fuel handling. Always be aware of the possibility of fuel splashing and observe fuel handling precautions. Failure to follow these instructions may result in injury.
WARNING: Make sure that the workshop area where the vehicle is being worked on is as clean and dust free as possible. Foreign matter from work on the clutch, brakes, or machining or welding operations can contaminate the fuel system and result in subsequent malfunction.
CAUTION: Always perform the cleaning procedure before making any repairs to the fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Open holes or lines should always be plugged with appropriate plugs.
CAUTION: Do not disassemble fuel injectors or clean their nozzles, even with ultrasonication. Always install new fuel injectors if necessary.
NOTE: Install new high pressure fuel feed lines.
1.
NOTE: Do not tighten the fuel manifold mounting bolts at this stage.
Install the fuel manifold.
2. Lubricate the high pressure fuel supply pipe nipple threads with a clean lubricant.
3.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the fuel line and the entry of foreign material into the fuel injection system.
CAUTION: Remove the plugs from the high pressure fuel supply line, fuel injector and fuel manifold as soon as possible. Failure to follow this instruction may result in dirt entering the fuel injection system.
NOTE: The fuel injector side connections are engraved with the cylinder number for easy identification of the high pressure fuel supply lines.
NOTE: Do not tighten the high pressure fuel feed nipple connections at this stage.
NOTE: Press down on the high pressure fuel supply line to keep the fuel line nipple in contact with the fuel rail cone when connected.
Connect the new high pressure fuel feed lines to the fuel rail. Discard plugs as they are no longer needed.
4.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the fuel line and the entry of foreign material into the fuel injection system.
CAUTION: Remove the plugs from the fuel supply line, fuel injectors and fuel manifold as soon as possible. Failure to follow this instruction may result in dirt entering the fuel injection system.
NOTE: Do not tighten the high pressure fuel feed nipple connections at this stage.
NOTE: Press down on the high pressure fuel supply line to keep the fuel line nipple in contact with the fuel injector cone when connected.
Connect the high pressure fuel lines to the fuel injectors. Discard plugs as they are no longer needed.
5.
NOTE: Be sure to install the clip in the same position it was in before removal.
Install the high pressure fuel supply pipe clamp to the high pressure fuel supply pipe.
6. Lubricate the high pressure fuel supply pipe nipple threads with a clean lubricant.
7.
CAUTION: Protect generator from contamination. Failure to follow this instruction may result in premature generator failure.
Cover the generator with lint-free material to prevent contamination.
8.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the fuel line and the entry of foreign material into the fuel injection system.
CAUTION: Remove the plugs from the high pressure fuel supply line, fuel pump and fuel manifold as soon as possible. Failure to follow this instruction may result in dirt entering the fuel injection system.
NOTE: Do not tighten the high pressure fuel feed nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the fuel line nipples in contact with the fuel pump and fuel rail cones when connected.
Install a new high pressure fuel supply line.
- 1. Connect the high pressure fuel supply line to the fuel manifold.
- 2. Connect the high pressure fuel supply line to the fuel pump.
- Discard plugs as they are no longer needed.
9. Tighten the fuel manifold mounting bolts.
10.
NOTE: Do not tighten the high pressure fuel feed line clamps at this stage.
NOTE: Clips must be installed in exactly the same position from which they were removed.
Install the high pressure fuel supply line clamps.
11.
CAUTION: The high pressure fuel supply nipple tightening tool should be installed at the top of the connection as this is where most of the material is found. Failure to follow this instruction may result in damage to the pin connection.
Tighten the nipple connections of the fuel supply lines on the fuel injectors (PCV hose shown removed for clarity).
12.
CAUTION: The high pressure fuel supply nipple tightening tool should be installed at the top of the connection as this is where most of the material is found. Failure to follow this instruction may result in damage to the pin connection.
Tighten the nipple connections of the fuel supply lines on the fuel manifold.
13.
CAUTION: The high pressure fuel supply nipple tightening tool should be installed at the top of the connection as this is where most of the material is found. Failure to follow this instruction may result in damage to the pin connection.
Tighten the nipple connections of the high pressure fuel supply lines.
- 1. Tighten the nipple connections of the high pressure fuel supply lines on the fuel manifold.
- 2. Tighten the nipple connection of the high pressure fuel supply line on the fuel pump.
14. Install the high pressure fuel supply bracket.
15.
NOTE: Clips must be installed in exactly the same position from which they were removed.
Tighten the clamps of the high pressure fuel supply lines.
16. Connect the fuel pressure sensor connector.
17. Remove lint free material from generator.
18. Install the charge air cooler and piping and dock the IAT sensor connector.
Vehicles with a 115 hp diesel engine
19.
CAUTION: Make sure the inside of the end of the charge air cooler exhaust pipe is clean and free of oil, as this reduces the friction when connecting the piping to the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the charge air cooler outlet pipe.
Vehicles with a 100 HP diesel engine
20.
CAUTION: Make sure the inside of the end of the charge air cooler exhaust pipe is clean and free of oil, as this reduces the friction when connecting the piping to the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the exhaust pipe to the charge air cooler. Connect the vacuum line to the charge air cooler outlet pipe.
All cars
21.
CAUTION: Make sure the inside of the charge air cooler intake pipe is clean and free from oil, as this impairs the adhesion between the piping and the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the charge air cooler intake pipe.
22. Install the air deflector.
23. Install the engine top cover.
24. Connect a wire of weight to the accumulator. See Section 414-01 for more information.
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