If a fuel line under the hood should become damaged or leaky, do not attempt
to weld or repair it. Replacement is required in all situations. Before disassembling
any of the lines, mark the location of the plastic or metal clamps which hold
the lines. These clamps are important in suppressing vibration which may loosen
or damage the lines. Clamps must be reinstalled in the exact position from which
they were removed.
- Clean all the connections carefully. Dirt is the enemy of the diesel fuel
system.
- Mark the position of all the line clamps and brackets.
- Loosen each end of each line at both the injector and the pump. Remove the
lines as an assembly with the clamps intact.
- Immediately plug the fittings on the injection pump and the injectors to
keep out dirt. This is very important.
- Disassemble the lines on the workbench, replacing the damaged line(s).
- When reinstalling, assemble the lines with the clamps correctly placed on
the workbench.
- Remove the plugs from the pump and injector ports. Install the fuel line
assembly and start each threaded fitting by hand. Tighten each fitting to
20 ft. lbs. (27 Nm).
- Double check that the line clamps are in place and secure. Bleed the fuel
system.
- Start the engine and check each joint for leaks. Because the system was
open, it may require a few seconds until it runs smoothly.
| Fig. 1: The fuel and vapor line assembly and component
location — 2.3L diesel engines
|
