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WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING: Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the high-pressure system can be as high as 1650 bar. Failure to follow this instruction may result in personal injury.
CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.
CAUTION: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking caps to any open orifices or lines.
CAUTION: Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.
NOTE:
If the fuel pump has suffered a major mechanical failure, new fuel injectors should also be installed.
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