Component Layout: Notes

Checking fuel system for leaks, see DIESEL FUEL INJECTION SYSTEM, LEAK TESTING 

Diesel injection pump, general information, see DIESEL INJECTION PUMP, GENERAL INFORMATION 

Diesel injection pump static timing, checking and adjusting, see DIESEL INJECTION PUMP STATIC TIMING, CHECKING AND ADJUSTING 

Max. engine speed (RPM), checking and adjusting, see IDLE SPEED, IDLE SPEED BOOST, MAXIMUM ENGINE SPEED (RPM) AND RESIDUAL FUEL DELIVERY, CHECKING AND ADJUSTING 

Diesel injection pump, servicing, see DIESEL INJECTION PUMP, SERVICING 

The following list pertains to Fig 1 .

1. Fuel filter 
   • Direction of flow indicated by arrows, see Figure
   • Do not interchange connections
2. O-ring 
   • Always replace
3. Control valve 
   • Location, see Figure
   • 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 
    • Removing and installing, see DIESEL INJECTION PUMP, REMOVING AND INSTALLING 
    • Static timing, checking and adjusting, see DIESEL INJECTION PUMP STATIC TIMING, CHECKING AND ADJUSTING 
    • With the exception of repairs described in DIESEL INJECTION PUMP, SERVICING  , an injector pump test bench is required for pump repairs; a faulty pump must be replaced
12. Fuel Injector 
    • Removing and installing, see FUEL INJECTORS, REMOVING AND INSTALLING 
    • Tightening torque: 70 Nm (52 ft lb)
    • Checking, see FUEL INJECTORS, SERVICING 
13. Heat shield 
    • Always replace
    • Installation position, see FUEL INJECTORS, REMOVING AND INSTALLING 
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, see DIESEL INJECTION PUMP CONNECTOR, STOPPING LEAKS 
17. Securing clip 
18. Shock absorber 
19. Fixture 
20. Mounting bracket 
21. Injection pump sprocket 
    • Removing: first remove injection pump, see DIESEL INJECTION PUMP, REMOVING AND INSTALLING 
22. 45 Nm (33 ft lb) 

Fig 1: Identifying Diesel Fuel Injection System Components