Fuel Return Hose Replace - Fuel Return to Fuel Injection Pump
FUEL RETURN HOSE REPLACEMENT - FUEL RETURN PIPE TO FUEL INJECTION PUMPREMOVAL PROCEDURE
1. Drain the cooling system.
2. Disconnect the negative battery cable.
3. Remove the air cleaner outlet duct
4. Loosen the charged air cooler outlet duct to intake 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.
5. Remove the charged air cooler outlet duct.
6. 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.
7. Remove the charged air cooler inlet duct from the turbocharger.
8. Remove the engine wiring harness.
9. Remove the water outlet tube.
10. Reposition the fuel hose clamps.
11. Remove the fuel hose from the fuel return rear pipe.
12. Remove the fuel hose from the fuel injection pump.
INSTALLATION PROCEDURE
1. Install the fuel hose to the fuel injection pump.
2. Install the fuel hose to the fuel return rear pipe.
3. Position the fuel hose clamps.
4. Install the water outlet tube.
5. Install the charged air cooler inlet duct to the turbocharger.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Align the mark on the duct (2) with the mark on the turbocharger.
7. Position the clamp (1) as shown for proper clearance.
Tighten
Tighten the clamp to 6 N.m (53 lb in).
8. Install the charged air cooler outlet duct to the intake.
9. Align the mark on the duct (3) with the mark on the turbocharger.
10. Position the clamp (1) as shown for proper clearance.
Tighten
Tighten the clamp to 6 N.m (53 lb in).
11. Install the air cleaner outlet duct
12. Connect the negative battery cable
13. Fill the cooling system.