Fuel Return Block Replacement

FUEL RETURN BLOCK REPLACEMENT

REMOVAL PROCEDURE




1. Drain the cooling system.
2. Remove the air cleaner outlet duct.
3. Loosen the charged air cooler outlet duct clamp (1).

IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

4. Remove the charged air cooler outlet duct.




5. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

6. Remove the charged air cooler inlet duct from the turbocharger.
7. Remove the engine wiring harness




8. Remove the heater pipe bolt and pipe.




9. Remove the fuel feed front pipe bracket nut.
10. Remove the fuel feed front pipe (1).
11. Remove the generator




12. Reposition the fuel hose clamps.
13. Remove the fuel feed hoses from fuel feed block (1).
14. Remove the fuel feed junction block bolt/nut and remove the feed block (1).
15. Remove the fuel return pipe to cylinder head bolt.
16. Remove the fuel return pipe (2).

INSTALLATION PROCEDURE

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: Always install new fuel line gaskets when servicing fuel lines.




1. Install the fuel return pipe (2).
2. Install the fuel return pipe to cylinder head bolt.

Tighten
Tighten the bolt to 15 N.m (11 lb ft).

3. Install the fuel feed junction block (1) and bolt/nut.

Tighten
Tighten the bolt/nut to 25 N.m (18 lb ft).

4. Install the fuel feed hoses to fuel feed block (1).
5. Reposition the fuel hose clamps.
6. Install the generator.




7. Install the fuel feed front pipe (1).
8. Install the fuel feed front pipe bracket nut.

Tighten
Tighten the nut to 8 N.m (70 lb in).




9. Install the heater pipe and bolt.

Tighten
Tighten the bolt to 20 N.m (14 lb ft).




10. Install the engine wiring harness
11. Install the charged air cooler inlet duct to turbocharger.
12. Align the mark on the duct (2) with the mark on the turbocharger.
13. Position the clamp (1) as shown for proper clearance.

Tighten
Tighten the clamp to 6 N.m (53 lb in).




14. Install the charged air cooler outlet duct to the intake.
15. Align the mark on the duct (3) with the mark on the turbocharger.
16. Position the clamp (1) as shown for proper clearance.

Tighten
Tighten the clamp to 6 N.m (53 lb in).

17. Install the air cleaner outlet duct.
18. Fill the cooling system.