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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised personnel that have the correct training. Before begining ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
Note: Put identification marks on all hoses on all hose assemblies and on wires and all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This will help to prevent fluid loss and this helps to keep contaminants from entering the system.
- The engine can have the ability to auto start. Ensure that the power supply is isolated before any service or repairs is performed.
- Turn the fuel supply to the OFF position.
- Turn the battery disconnect switch to the OFF position.
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Illustration 1 g01617993 - Loosen hose clamp and disconnect breather hose from the valve mechanism cover.
- Remove bolts (2), washers (3) and spacers (4) from cover (1) and remove the cover. If necessary, remove grommets (5) from cover (1).
- For sea water cooled engines, remove the bracket for the aftercooler and the heat exchanger. For keel cooled engines, remove the bracket for the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove" for the correct procedures. Refer to Disassembly and Assembly, "Heat Exchanger- Remove" for the correct procedures.
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Illustration 2 g01525940 - Disconnect harness assembly from fuel pressure sensor (14).
- Disconnect the tube assembly from fuel pressure relief valve (9) on fuel manifold (8). Immediately cap the open port of fuel pressure relief valve (9) with a new cap. Immediately plug the open end of the tube assembly with a new plug.
- Remove banjo bolts (10) and sealing washers (13) from the leak off pipe (11) and leak off pipe (16).
- Remove bolts (15) from tube clips (17) and position tube assembly (16) away from fuel manifold (8).
- Remove bolts and washers from clamps (7) and clamps (12). Remove clamps (7) and clamps (12) from the fuel injection lines (6).
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Illustration 3 g01525942 - If necessary, disconnect harness assembly (20) and harness assembly (21) from fuel injection pump (18). Slide locking tab (22) into the unlocked position. Disconnect harness assembly (21) from position sensor (23). Disconnect harness assembly (20) from fuel injection pump (18). Position harness assembly (20) and harness assembly (21) so that the harness assemblies are clear of fuel injection line (19).
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Illustration 4 g01525947 Show/hide table
Illustration 5 g01525949 - Remove bolts (24) from tube clips (25) that secure fuel injection line (19). Loosen allen head screws (26). Position the tube clips in order to allow removal of the fuel injection line.
- Remove the assembly of fuel injection line (19).
- Plug all open ports immediately in fuel manifold (8) and in fuel injection pump (18).
- Remove allen head screws (26) and tube clips (25) from fuel injection line (19). Discard the fuel injection line.
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Illustration 6 g01637653 Show/hide table
Illustration 7 g01637875 - Remove fuel injection line (27) and fuel injection line (30). Discard the fuel injection lines.
- Loosen the nuts on fuel injection lines (28), (29), (31) and (32).
- Remove bolts (36) and bracket (35).
- Remove fuel injection lines (28), (29), (31) and (32) from fuel manifold (8). Discard the fuel injection lines.
- Remove fuel manifold (8). Plug the open ports in fuel manifold (8) immediately.
- Remove seals (33) from the electronic unit injector. Plug the open ports of the electronic unit injector immediately.
