FUEL SYSTEM
TABLE OF CONTENTS
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FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM
PRESSURE ...........................1
WARNING ............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH
PRESSURE FUEL LINES .................1
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM .............................2
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM COMPONENTS ............2
STANDARD PROCEDURE -
DISCONNECTING AND CONNECTING
FUEL LINES ..........................2
STANDARD PROCEDURES - DRAINING
WATER FROM FUEL FILTER ..............2
STANDARD PROCEDURE - LOW
PRESSURE FUEL PUMP TEST ............3
FUEL DELIVERY ..........................4
FUEL INJECTION ........................17
FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE INJECTORS. THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
WARNING
WARNING: UNDER NO CIRCUMSTANCES SHOULD
GASOLINE BE MIXED WITH DIESEL FUEL (NOT
EVEN DURING WINTER). THE HIGH PRESSURE
PUMP IS LUBRICATED BY DIESEL FUEL. IMMEDI-
ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS-
ING REPLACEMENT AND FLUSHING OF THE
COMPLETE DIESEL FUEL SYSTEM. HIGH PRES-
SURE PUMP SEIZURE WILL CAUSE METAL PARTI-
CLES TO SPREAD THROUGH OUT THE FUEL
CIRCUIT. ALL CDI FUEL SYSTEM COMPONENTS
CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO
BE EXCHANGED AND THE LINES FLUSHED.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
(Refer to 14 - FUEL SYSTEM - WARNING). High-
pressure fuel line leaks can cause starting problems
and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES,
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR
HAND NEAR A SUSPECTED LEAK. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Start the engine. Move the cardboard over the
high-pressure fuel lines and check for fuel spray onto
the cardboard (Fig. 1). If a high-pressure line connec-
tion is leaking, tighten the connection and perform
the Fuel System Air Purge procedure (Refer to 14 -
FUEL SYSTEM - STANDARD PROCEDURE).
Replace damaged, restricted or leaking high-pressure
fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines cannot con-
tact each other or other components. Do not
attempt to weld high-pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high-pressure fuel line is
necessary.
VA FUEL SYSTEM 14 - 1
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