Removal Procedure
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Glasses Warning .
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (without KL9) , or Battery Negative Cable Disconnection and Connection (with KL9)
- Intake Manifold Cover - Remove - Intake Manifold Cover Replacement
- Separate the charge air cooler outlet air hose from the throttle body and set aside. Charge Air Cooler Outlet Air Hose Replacement
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NOTE:
Lay a lint-free cloth under the fuel feed intermediate pipe to absorb any excess fuel spillage.
Remove the fuel injection fuel feed pipe clip bolt (3).
- Loosen the fuel feed intermediate pipe fittings (2, 5).
- Remove the fuel feed intermediate pipe (4) from the fuel injection fuel rail (1) and the fuel pump (6).
- Remove and DISCARD the fuel feed intermediate pipe (4).
High pressure fuel feed pipes are one time use only. ALWAYS install a NEW high pressure fuel feed pipe if the pipe is removed OR the fittings are loosened.