Fuel Delivery System Description
Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage.
Fuel can also irritate skin and eyes. To prevent this, always complete the following “Precautions”.
Never disconnect fuel high-pressure line between injection pump and injectors under pressure, or fuel can be sprayed out under pressure.
Be sure to confirm that fuel high-pressure line is not under pressure referring Fuel Pressure Relief Confirmation Procedure:K9K before disconnecting. If it is under pressure, wait till it is not under pressure.
Before servicing the fuel delivery system, read all contents described in Precautions otherwise not only the fuel delivery system but also the engine might be damaged.
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
damage or destruction of the high pressure injection system and the engine.
seizing or leaking of a component.
When servicing on the high pressure direct injection system, must be performed under very clean conditions. This means that no impurities (particles a few microns in side) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
Contamination is caused by:
metal or plastic chips,
fibres: boxes, brushes, paper, clothing, cloths,
foreign bodies such as hair,
ambient air,
It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection problems.
The system can inject the diesel into the engine at a pressure up to 1600 bars. Before carrying out any work, check that the injector rail is not under pressure and that the fuel temperature is not too high.
Ensure that you have the plugs (1) for the unions to be opened. Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away.
1. Plug (Cap set available as a spare part: parts number 15733-84A00) icon : Do not reuse.
Ensure that you have hermetically resalable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away.
Make sure that lint-free towelettes. The use of a normal cloth or paper for cleaning purposes is forbidden.
These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be used once.
Instructions to be followed before opening the fuel circuit.
For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
Use a brush and thinners to clean the connections to be opened.
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection system zone). Check that no bristles remain adhered.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves, cover these with latex gloves.
Instructions to be followed during the operation.
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system by using the plug (available as a spare part). They must not, under any circumstances, be reused.
Close the hermetically seated bag, even if it has to be reopened shortly afterwards.
Ambient air carries contamination.
All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
These items are likely to allow impurities to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.