Fuel Delivery and Air Induction: Service Precautions

Low-Pressure Lines
- the fuel supply line from fuel tank to fuel transfer (lift) pump.
- the fuel return line back to fuel tank.
- the fuel drain manifold line at rear of cylinder head.
- the fuel supply line from fuel filter to fuel injection pump.

High-Pressure Lines
- the fuel line from fuel injection pump to overflow valve.
- the fuel line from fuel injection pump to fuel rail.
- the 6 fuel lines from fuel rail up to injector connector tubes


WARNING: HIGH-PRESSURE FUEL LINES DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS. THIS MAY BE AS HIGH AS 160,000 kPa (23,206 PSI). USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN.

High-Pressure Lines

CAUTION: The high-pressure fuel lines must be held securely in place in their holders. The lines cannot contact each other or other components. Do not attempt to weld high-pressure fuel lines or to repair lines that are damaged. If lines are ever linked or bent, they must be replaced. Use only the recommended lines when replacement of high-pressure fuel line is necessary.

High-pressure fuel lines deliver fuel (under pressure) of up to approximately 160,000 kPa (23,206 PSI) from the injection pump to the fuel injectors. The lines expand and contract from the high-pressure fuel pulses generated during the injection process. All high-pressure fuel lines are of the same length and inside diameter. Correct high-pressure fuel line usage and installation is critical to smooth engine operation.

WARNING: USE EXTREME CAUTION WHEN INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY IF CONTACT IS MADE WITH THE SKIN. DIAGNOSIS AND TESTING - HIGH-PRESSURE FUEL LINE LEAKS