Fuel Return Junction Block Replacement

Fuel Return Junction Block Replacement

Removal Procedure




1. Remove the generator.
2. Remove the fuel filter/heater element housing to fuel feed block fuel hose.
3. Remove the intake manifold tube.
4. Remove the water outlet tube.
5. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.




6. Remove the fuel hose (4) from the fuel injection fuel feed manifold.




7. Reposition the fuel return hose clamp (1) at the fuel injection fuel feed manifold.




8. Remove the fuel pipe clip bolt (1) and clip.
9. Disconnect the fuel injector fuel feed pipe (2) from the fuel injection fuel feed manifold.






Important: Note the routing of the fuel injection fuel feed manifold pipes under the exhaust gas recirculation (EGR) bracket.

10. Remove the fuel injection fuel feed manifold from the fuel return hose and the vehicle.

Installation Procedure






Important: Ensure to route the fuel injection fuel feed manifold pipes under the EGR bracket.

1. Install the fuel injection fuel feed manifold to the vehicle and the fuel return hose.




2. Connect the fuel injector fuel feed pipe (2) to the fuel injection fuel feed manifold.

Notice: Refer to Fastener Notice.

3. Install the fuel pipe clip and bolt (1).

Tighten the bolt to 24 N.m (18 lb ft).




4. Position the fuel return hose clamp (1) at the fuel injection fuel feed manifold.




5. Install the fuel hose (4) to the fuel injection fuel feed manifold.




6. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
7. Install the water outlet tube.
8. Install the intake manifold tube.
9. Install the fuel filter/heater element housing to fuel feed block fuel hose.
10. Install the generator.
11. Prime the fuel system. Refer to Fuel System Priming.
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.