Fuel Return Pipe Replacement

FUEL RETURN PIPE REPLACEMENT

REMOVAL PROCEDURE




1. Drain the cooling system.
2. Disconnect the negative battery cable.
3. Remove the air cleaner outlet duct-Refer to Air Cleaner Outlet Duct Replacement.
4. 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 damage-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 damage-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 fuel feed front pipe bracket nut.
10. Remove the fuel feed front pipe (1).




11. Reposition the fuel injection fuel feed front hose clamps.
12. Remove the fuel injection fuel feed front hose.
13. Remove the glow plug relay.




14. Remove the fuel return rear pipe bolt (2) from the cylinder head.




15. Remove the fuel pipe clip bolt and clip.




16. Remove the fuel return rear pipe bolt and pipe.
17. Remove and discard the return pipe gaskets.

INSTALLATION PROCEDURE

IMPORTANT: Always install NEW copper gaskets onto the fuel injector fuel return pipe.




1. Install NEW the return pipe gaskets.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel return rear pipe and bolt.

Tighten
Tighten the bolt to 27 N.m (19 lb ft).




3. Install the fuel pipe clip and bolt.

Tighten
Tighten the bolt to 16 N.m (11 lb ft).




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

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

5. Install the glow plug relay.




6. Install the fuel injection fuel feed front hose.
7. Reposition the fuel injection fuel feed front hose clamps.




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

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




10. Install the engine wiring harness.
11. Install the charged air cooler inlet duct to the 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. Connect the negative battery cable.
19. Fill the cooling system.