High-Pressure Fuel System Bleeding

High-Pressure Fuel System Bleeding

Pneumatic Vacuum Gun

WARNING:
- Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to follow this instruction may result in personal injury.
- Place the vehicle in a well ventilated, quarantined, area and arrange 'No Smoking/Fuel Fumes' signs about the vehicle.
- Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete.
- Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system can be as high as 1650 bar. Failure to follow this instruction may result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
- After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.
- If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.
- If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.
- Wash hands thoroughly after handling fuel, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTION:
- Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
- Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow these instructions may result in foreign matter ingress to the fuel injection system.
- The low pressure fuel system bleeding procedure must be carried out before this procedure is carried out, or the engine is attempted to be started, following removal or replacement of any low pressure fuel system component. Failure to follow this instruction may result in damage to the fuel injection pump.
- The engine must not be cranked using the starter motor for more than 30 seconds. The starter motor must be allowed to cool for at least 5 minutes after cranking for 30 seconds. Failure to follow these instructions will result in damage to the starter motor.

NOTE:
- If a new fuel filter is to be installed, make sure the fuel filter is installed AFTER the high-pressure fuel system has been bled.
- This procedure is necessary if the fuel injection pump, or the fuel line between the fuel filter and the fuel injection pump is removed, drained of fuel or replaced.

1. Bleed the low pressure fuel system.
2. Remove the oil filler cap.







3. Remove the engine cover.







4. Detach the high-pressure fuel supply line clamp.







5. Clean around the high-pressure fuel supply lines, the fuel injection diverter rail and the fuel injection supply manifolds.

CAUTION:
- Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and fuel injection diverter rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
- Make sure the tool used to loosen the high-pressure fuel supply line unions is used at the top the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.

6. Loosen the high-pressure fuel supply lines.







7. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel injection diverter rail and the fuel injection supply manifolds.
8. Remove and discard the high-pressure fuel supply line.







9. Install a new high-pressure fuel supply line, but do not fully tighten the unions at this stage.







10. Position suitable lint free material under the left-hand high-pressure fuel line unions to catch escaping fuel.
11. Turn the ignition switch to the RUN position for 20 seconds.
12. If fuel does not appear at the fuel line unions after 20 seconds, allow the starter motor to cool for five minutes.
13. Repeat steps 11 and 12 until fuel appears at the fuel line unions.

CAUTION: Make sure the tool used to tighten the high-pressure fuel supply line unions is used at the top of the unions as this is where there is most material. Failure to follow this instruction may result in damage to the unions.

14. Tighten the the high-pressure fuel supply line unions.
- Tighten the high-pressure fuel supply line in the sequence shown in four stages:

Stage 1: Tighten the high-pressure fuel supply line union 1 to 15 Nm.
Stage 2: Tighten the high-pressure fuel supply line union 2 to 15 Nm.
Stage 3: Tighten the high-pressure fuel supply line union 1 to 30 Nm.
Stage 4: Tighten the high-pressure fuel supply line union 2 to 30 Nm.







15. Attach the high-pressure fuel supply line clamp.
- Tighten to 10 Nm.







WARNING: Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the high-pressure system can be as high as 1650 bar. Failure to follow this instruction may result in personal injury.

17. Install the engine cover.







18. Install the oil filler cap.