Defender. Manual - part 125
The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to
prevent fire and explosion.
Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable
vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related
components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result
in personal injury.
If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical
attention.
Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop,
seek medical attention.
Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can
be as high as 2000 bar (29,008 lb-sq-in). Failure to follow this instruction may result in personal injury.
• CAUTIONS:
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 new blanking plugs
to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection
system.
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.
Do not disconnect the fuel injector electrical connectors with the engine running. Failure to follow this instruction
may result in serious damage to the engine.
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.
1.
CAUTION: Only tighten the bolts finger-tight at this
stage.
• NOTE: Clean the component mating faces.
Install the fuel rail.
Install the bracket.
Loosely install the bolts.
2. CAUTIONS:
Maintain pressure on the high-pressure fuel supply line to
keep the olives in contact with the fuel injectors and the fuel
rail cones while installing unions.
Do not allow the unions to hit the olive ends of the high-
pressure fuel supply line as this may damage the ends of the
high-pressure fuel supply line and allow foreign matter to enter
the fuel injection system.
Only tighten the unions finger-tight at this stage.
• NOTE: Remove and discard the blanking caps.
Loosely install the new high-pressure fuel rail supply line.
3. CAUTIONS: