Removal

REMOVAL

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.




1. Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.

2. Thoroughly clean fuel lines at both ends.

3. If removing fuel line at either No. 1 or No. 2 cylinder, the intake manifold air heater elements must first be removed from top of intake manifold.

4. If removing fuel line at No. 6 cylinder, a bracket (1) is located above fuel line connection at cylinder head. Two bolts secure this bracket to rear of cylinder head. The upper bolt hole is slotted. Loosen (but do not remove) these 2 bracket bolts. Tilt bracket down to gain access to No. 6 fuel line connection.

5. Remove engine lift bracket (if necessary).




6. Remove necessary insulated fuel line support clamps (2) at intake manifold. DO NOT remove insulators from fuel lines.

7. Place shop towels around fuel lines at fuel rail and injectors. If possible, do not allow fuel to drip down side of engine.

CAUTION: When loosening or tightening high-pressure lines attached to a separate fitting , use a back-up wrench on fitting. Do not allow fitting to rotate. Damage to both fuel line and fitting will result.




8. Carefully remove each fuel line from engine. Note position of each while removing. Do not bend lines while removing.