Operation and maintenance manual

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FuelSystemRepairSummary
Component To
Be Replaced
Tools Preparatory Steps
Lift Pump
13,14 and 17 mm Wrenches Clean debris.
High Pressure Lines
13 mm Socket, 14,17, and 19mm Open End Wrenches and
a Torque Wrench
Clean debris.
Injector Fuel Drain
10 mm and 19 mm Open End Wrenches, 10 Manifold mm
and 13 mm Sockets, and a Torque Wrench.
Manifold mm and 13 mm Sockets, and a Torque Wrench
Injectors Ratchet, 24 mm Socket (deep well), and a Torque Wrench
Disconnect the
high pressure
lines Wrench and
fuel drain
manifold.
Injection Pump
10 mm Wrench, Ratchet, 22 mm Socket, 75 mm T-Bar
Puller (w/2 8 mm cap screws) 1/2 in. open end wrench flat
Screwdriver 13 mm Socket, 13 mm Wrench, Hammer, flat
Chisel and a Torque Wrench.
Robert Bosch 24 mm Wrench, Lucas CAV 22 mm Wrench
Remove high
pressure lines,
supply line and
return line.
Remove the AFC
air line, oil line (s),
fuel shutoff
solenoid and
control linkage.
Fuel Solenoid
Robert Bosch 24 mm Wrench, Lucas CAV 22 mm Wrench
Label and
disconnect wiring.
Fuel Filter Head
24 mm, 75-80 mm and 90-95 mm Filter Wrench
Clean debris.
FuelSystemComponents‐Cleaning
Thoroughly clean all fittings and components
before removal. Make sure that the debris, water,
steam, or cleaning solution does not reach the
inside of the fuel system.