Removal and installation the fuel manifold (Freelander 2)

Avoid open flames, sparks or flammable materials.

After stopping the engine, wait at least one minute before performing any repairs to the fuel injection system.

Clean the area around the element and remove any foreign material. Plug all openings. Use new caps.

Bleed the fuel system by cranking the engine to release air from the system.

NOTE: The fuel pressure and temperature sensors are an integral part of the fuel rail and cannot be replaced individually.

Removal

1. Disconnect the battery ground cable. Refer to procedure: Specifications (414-00 Charging System - General Information, Specifications).

2. Remove the engine trim. Refer to procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior Trim, Removal and Installation).

3. Remove the four high pressure fuel supply lines and discard them.

Make sure both ends of the fuel line remain in contact until both union nuts have been removed and the area around the connections has been thoroughly cleaned.

Plug all openings. Use new caps.

7.

CAUTION: Plug all openings. Use new caps.

9. Release the high pressure fuel line between the fuel pump and the fuel rail.

Clean the area around the element and remove any foreign material. Plug all openings. Use new caps.

NOTE: Use an additional key to prevent the element from turning.

10. Remove the high pressure fuel line between the fuel pump and the fuel rail and discard it.

Installation

1. Install a new high pressure fuel line between the fuel pump and the fuel rail.

CAUTION: Clean the area around the element and remove any foreign material.

2. Install the fuel rail. Tightening torque: 22 Nm

CAUTION: Clean the area around the element and remove any foreign material.

3. Connect the fuel pump to the high pressure fuel line of the fuel rail, but do not tighten it completely at this stage.

CAUTION: Clean the element from dirt and grease.

4. Tighten the high pressure fuel line. Tightening torque: Step 1: 22 Nm. Step 2: 25 Nm

5. Install the high pressure fuel line mounting bolt. Tightening torque: 8 Nm

6. Install the fuel pump bracket. Tightening torque: 8 Nm

7. Install the EGR pipe. Tightening torque: 10 Nm

8. Install the ventilation duct.

9. Connect the low pressure fuel return line.

10. Install the new high pressure fuel lines, but do not tighten them completely at this stage.

Clean the area around the element and remove any foreign material. The high-pressure fuel line fuel injectors must be installed in pairs. Injectors 2 and 3, 1 and 4, respectively.

11. Tighten the new high pressure fuel supply lines. Tightening torque: Step 1: 22 Nm. Step 2: 25 Nm

12. Install the engine cover. Refer to procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior Trim, Removal and Installation).

13. Connect the ground cable to the battery. Refer to Procedure: Specifications (414-00 Charging System - General Information, Specifications).

14. Remove air from the fuel system.

CAUTION: Bleed air from the fuel system by cranking the engine to release air from the system.