Contents: Removal ⇩ Installation ⇩
Removal
CAUTION: Wait at least 30 seconds after stopping the engine before attempting any repairs to the high pressure fuel injection system. Failure to do so could result in personal injury.
CAUTION: Do not smoke or allow lighted cigarettes or open flames of any type when working on or near fuel related items. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in personal injury.
CAUTION: When performing the following work, care must be taken when handling fuel. Always be prepared for possible fuel splashes and follow safe fuel handling procedures. Failure to follow these instructions may result in personal injury.
CAUTION: Do not perform any repairs to the fuel system while the engine is running. Fuel pressure in the system can reach 1650 bar. Failure to follow this instruction may result in personal injury.
CAUTION: Make sure that the service area where the vehicle is being worked on is as clean and dust-free as possible. Dirt and dust from clutch, brake, machining or welding operations can contaminate the fuel system and cause malfunctions.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to do so may result in contamination entering the fuel injection system.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Be sure to plug any open holes or lines. Failure to do so may result in contaminants entering the fuel injection system.
CAUTION: Do not remove the FRP sensor from the fuel rail.
NOTE: The fuel rail and fuel rail pressure (FRP) sensor are supplied as a unit only. Do not remove the FRP sensor from the fuel rail. If a new FRP sensor is required, a new fuel rail assembly must be installed.
1. Disconnect the ground cable from the battery. For more information, refer to Specification.
2. Remove the engine cover. For more information, refer to Engine Cover - 2.7L Diesel (12.30.50)
3. Disconnect the low pressure fuel lines. Insert plugs into the open holes.
4. Disconnect both hoses from the exhaust gas recirculation (EGR) coolant bypass tube. Restring the EGR coolant hoses to minimize coolant loss.
5. Remove the EGR coolant bypass pipe. Unscrew the 2 mounting bolts.
6.
NOTE: Left side shown, work on the right is similar.
Release the right and left high pressure fuel supply lines. Remove the bolt.
7.
CAUTION: Ensure that the high pressure fuel supply line remains in contact with the fuel rail and fuel manifold until both connections have been disconnected and cleaned. Failure to do so may allow contaminants to enter the fuel injection system.
NOTE: Left side shown, work on the right is similar.
Information obtained from the website: www.LRman.ru
Remove and discard the right and left high pressure fuel supply lines. Insert plugs into the open holes.
8.
CAUTION: Ensure that the high pressure fuel supply line remains in contact with the fuel pump and fuel rail until both connections have been disconnected and cleaned. Failure to do so may allow contaminants to enter the fuel injection system.
NOTE: For clarity, the crankcase ventilation oil separator is shown removed.
Remove and discard the high pressure fuel supply line. Insert plugs into the open holes.
9. Release the low pressure fuel line.
- Disconnect the low pressure fuel line.
- Insert plugs into the open holes.
10. Disconnect the fuel rail pressure (FRP) sensor electrical connector. Release the fuel supply system wiring harness.
11. Remove the fuel distribution rail assembly. Unscrew the 2 studs.
Installation
CAUTION: Do not remove the FRP sensor from the fuel rail.
NOTE: The fuel rail and FRP sensor are supplied as a unit only. Do not remove the FRP sensor from the fuel rail. If a new FRP sensor is required, a new fuel rail assembly must be installed.
1. Install the FRP sensor and fuel rail assembly. Install the fuel rail mounting studs, but do not tighten them fully at this stage.
2. Connect the FRP sensor electrical connector. Connect the fuel injection system wiring harness.
3. Install a new high pressure fuel supply line.
- Remove plugs from exposed connections.
- Install the new high pressure fuel supply line, but do not tighten the connections yet.
- Tighten the fuel rail mounting studs to 23 Nm.
- Step 1: Tighten the high pressure fuel supply line union on the fuel pump side ' (tightening torque 15 Nm).
- Step 2: Tighten the high pressure fuel supply line union on the fuel rail to 15 Nm.
- Step 3: Tighten the high pressure fuel supply line union on the fuel pump side ' (tightening torque 30 Nm).
- Step 4: Tighten the high pressure fuel supply line union on the fuel rail to 30 Nm.
- Remove plugs from exposed connections.
- Connect the low pressure fuel line.
- Remove plugs from exposed connections.
- Install the new high pressure fuel supply lines, but do not tighten them permanently.
- Step 1: Tighten the high pressure fuel supply line union on the fuel rail to 15 Nm.
- Step 2: Tighten the high pressure fuel supply line union on the fuel rail to 15 Nm.
- Step 3: Tighten the high pressure fuel supply line union on the fuel rail to 30 Nm.
- Step 4: Tighten the high pressure fuel supply line union on the fuel rail to 30 Nm.
7. Install the EGR coolant bypass tube.
- Install 2 EGR coolant bypass pipe mounting bolts.
- Tighten to 13 Nm.
9. Connect the low pressure fuel lines. Remove the plugs from the exposed connections.
10. Install the engine cover. For more information, refer to Engine Cover - 2.7L Diesel (12.30.50)
11. Connect the ground cable to the battery. For more information, refer to Specification.
12. Bleed the fuel system. For more information, refer to Bleeding the Low-Pressure Fuel System (19.50.07)
13. Check the coolant level and top up if necessary.
Comments on this article