Fuel Injection Lines – Remove and install


Removal procedure

Isolate the fuel supply. Isolate the electrical supply.


Remove the two plastic clamps (2) from the fuel injection lines (1). Discard the plastic clamps.
Slide the dust seal (3) from the nut on the fuel injection line (1).
Disconnect the fuel injection line (1) at the electronic unit injector (4).
Disconnect the fuel injection line (1) at the fuel manifold (5).
Remove the fuel injection line (1). Discard the fuel injection line. Clean up any spillage of fuel immediately.
Plug the open port in the fuel manifold (5) immediately. Use Tooling in order to plug the open port in the fuel manifold.
Remove the seal (6) from the electronic unit injector (4) and the base of the valve mechanism cover (not shown). The seal can be damaged by contact with fuel.
Plug the open port in electronic unit injector (4) immediately. Use Tooling in order to plug the open port in the electronic unit injector.
Repeat Steps in order to remove the remaining fuel injection lines from the fuel manifold to the electronic unit injectors.


Disconnect the harness assembly (9) from the fuel injection pump (8). Slide the locking tab (10) into the unlocked position. Disconnect the harness assembly (9) from the position sensor (11). Position the harness assembly (9) so that the harness assembly is clear of the fuel injection line (7).


Assembly of the tube clip
Remove the fasteners (12) from the three tube clips (13) that secure the fuel injection line (7). Loosen the three allen head screws (14). Position the tube clips in order to allow removal of the fuel injection line.
Disconnect the fuel injection line (7) at the fuel injection pump (8).
Disconnect the fuel injection line (7) at the fuel manifold (5).


Plug all open ports immediately. Use Tooling in order to plug the open ports in the fuel manifold (5) and in the fuel injection pump (8).
Remove the fuel injection line (7). Clean up any spillage of fuel immediately.
Remove the allen head screws (14) and the assemblies of the three tube clips (13) from fuel injection line (7). Discard the fuel injection line.

Installation procedure

The following procedure should be adopted in order to install the fuel injection lines when the electronic unit injectors or the fuel manifold have not been removed.

Assembly of the tube clip
Loosely install the assemblies of the three tube clips (13) and the allen head screws (14) to the fuel injection line (7).
Place the fuel injection line (7) in position.
Remove the caps from the port in the fuel injection pump (8) and from the appropriate port in the fuel manifold (5). Remove the caps from the new fuel injection line (7).
Loosely connect the nuts at both ends of the fuel injection line (7), to the fuel manifold (5) and to the fuel injection pump (8). Ensure that the ends of the fuel injection line are correctly seated in the fuel injection pump and in the fuel manifold.
Use Tooling to tighten the nuts on the fuel injection line (7) to a torque of 30 N·m (22 lb ft).
Install the setscrews (12) for the three tube clips (13) that secure the fuel injection line (7). Tighten the setscrews (12) to a torque of 22 N·m (16 lb ft). Tighten the M5 allen head screws (14) to a torque of 10 N·m (89 lb in). Ensure that fuel injection line does not contact any other engine component.

Connect the harness assembly (9) to the position sensor (11). Slide the locking tab (10) into the locked position. Connect the harness assembly (9) to the fuel injection pump (8).

Thoroughly clean the seal (6). Inspect the seal for damage. If necessary, replace the seal. The seal can be damaged by contact with fuel. If the seal has been in contact with fuel for a prolonged period, the seal should be replaced.
Install the seal (6) to the electronic unit injector (4). Ensure that the flange on the seal is flush with the valve mechanism cover base.
Remove the caps from the new fuel injection line (1). Ensure that a new dust seal (3) is installed to the fuel injection line.
Remove the caps from the electronic unit injector (4) and from the appropriate port in the fuel manifold (5).
Loosely connect the nuts at both ends of the fuel injection line (1), to the electronic unit injector (4) and to the appropriate port in the fuel manifold (5). Ensure that the ends of the fuel injection line are correctly seated in the electronic unit injector and in the fuel manifold.
Use Tooling to tighten the nuts on the fuel injection line (1) to a torque of 30 N·m (22 lb ft). Slide the dust seal (3) into position over the nut on the fuel injection line. Ensure that the dust seal (3) is in contact with the seal (6).
Follow Steps 8 through 13 in order to install the remaining fuel injection lines.
Install two new clamps (2) to the fuel injection lines. Ensure that the clamps are fully closed in order to retain the fuel injection lines. Ensure that fuel injection lines do not contact any other engine component.
Restore the fuel supply. Restore the electrical supply.
Remove the air from the fuel system.