Diesel Fuel Injection System, Component Layout

Diesel Fuel Injection System, Component Layout

CAUTION!
- Secure all fuel hoses with hose clips.
- Always replace seals and gaskets.
- Observe rules of cleanliness

Checking fuel system for leaks, refer to "Fuel System, Leak Checking". Testing and Inspection





1 - Fuel filter
- Direction of flow indicated by arrows See Fig. 1
- Do not interchange connections
2 - O-ring
- Always replace
3 - Control valve
- Location See Fig. 1
- When replacing filter, release spring clip and remove control valve with fuel lines connected
4 - Fuel return line
- To fuel tank
5 - Retaining clip
6 - Fuel supply line
- From fuel tank
7 - Drain plug
- To bleed:
- Remove retaining clip for control valve.
- Remove control valve with fuel lines connected.
- Loosen plug and let 100 cc (3.4 oz.) of fuel run out.
- Re-install plug and control valve.
8 - 25 Nm (18 ft lb)
9 - Banjo bolt
- For fuel return line
- Is marked with "OUT"
- Tightening torque: 25 Nm (18 ft lb)
10 - Fuel Cut-Off Valve -N109-
- Must click when ignition is switched on and off
- Tightening torque: 40 Nm (30 ft lb)
11 - Diesel injection pump
- With the exception of repairs described in "Diesel Injection Pump, Servicing" Service and Repair, an injector pump test bench is required for pump repairs; a faulty pump must be replaced.
12 - Fuel Injector
- Tightening torque: 70 Nm (52 ft lb)
13 - Heat shield
- Always replace
14 - Fuel Injector lines
- Tightening torque: 25 Nm (18 ft lb)
- Remove with tool 3035
- Always remove complete set of lines
- Do not alter shape
15 - 15 Nm (11 ft lb)
- May be tightened to max.25 Nm (18 ft lb) to stop leaks
16 - Connector
- Removing, installing and stopping leaks, refer to "Diesel Injection Pump Connector, Stopping Leaks". Service and Repair
17 - Securing clip
18 - Shock absorber
19 - Fixture
20 - Mounting bracket
21 - Injection pump sprocket
22 - 45 Nm (33 ft lb)





Fig. 1 Fuel filter and control valve connections
1 - Supply from fuel tank
2 - Supply to injection pump
3 - Return from injection pump
4 - Return to fuel tank (marked with arrow)
5 - Retaining clip