:	Jul 15, 2008

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Disconnect the battery ground cable.

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Remove the intake air shutoff throttle.

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Disconnect the low-pressure fuel lines.   Install blanking caps to the exposed ports.

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Disconnect both exhaust gas recirculation (EGR) coolant cross-over pipe hoses.   Clamp the EGR coolant hoses to minimize coolant loss.

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Remove the EGR coolant cross-over pipe.   Remove the two retaining bolts.

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Disconnect the engine oil pressure (EOP) sensor electrical connector.

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: The O-ring seal is to be reused unless damaged. Using the special tool, remove the oil filter element.   Loosen the element cover 4 complete turns to allow engine oil to drain from the filter cover.   Remove element cover.   Clean the immediate area.

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:   Left-hand shown, right-hand similar. Remove the breather pipes.

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Disconnect the glow plug electrical connectors.

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Disconnect the low-pressure fuel lines.   Install blanking caps to the exposed ports.

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: Make sure that the high-pressure fuel supply line remains in contact with the fuel pump and fuel injection diverter rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system. :   Crankcase vent oil separator shown removed for clarity. Remove and discard the high-pressure fuel supply line.   Install blanking caps to the exposed ports.

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Remove the low-pressure fuel line.   Disconnect the low-pressure fuel line.   Release the low-pressure fuel line.   Install blanking caps to the exposed ports.

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:   Right-hand shown, left-hand similar. Remove the glow plug wires.

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Reposition the crankcase vent oil separator.

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Disconnect the fuel injection pump electrical connectors.

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Disconnect the fuel rail pressure (FRP) sensor electrical connector.   Release the fuel charging wiring harness.

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: The O-ring seals are to be reused unless damaged. :   Remove the crankcase vent oil separator drain tube seal prior to the removal of the crankcase vent oil separator. :   Using a suitable adhesive tape, protect the oil cooler. Remove the crankcase vent oil separator.

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: The O-ring seals are to be reused unless damaged. Position the crankcase vent oil seperator, but do not fully install at this stage.   Clean the immediate area.

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Connect the FRP sensor electrical connector.   Attach the fuel charging wiring harness.

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Install the crankcase vent oil separator.

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Connect the fuel injection pump electrical connectors.

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Install the glow plug wires.

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Install the low-pressure fuel line.   Remove the blanking caps from the ports.   Connect the low-pressure fuel line.   Attach the low-pressure fuel line.

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Install the new high-pressure fuel supply line.   Remove the blanking caps from the ports.   Install the new high-pressure fuel supply line, but do not tighten unions at this stage.   Stage 1: Tighten the high-pressure fuel supply line union at the fuel pump to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel pump to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel injection diverter rail to 30 Nm (22 lb.ft).

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Connect the low-pressure fuel lines.   Remove the blanking caps from the ports.

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Connect the glow plug electrical connectors.

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Install the breather pipes.

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: The O-ring seal is to be reused unless damaged. Install the oil filter element.   Clean the components.   Tighten the oil filter element cover to 25 Nm (18 lb.ft).

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Connect the EOP sensor electrical connector.

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Install the EGR coolant cross-over pipe.   Install the two retaining bolts.   Tighten to 13 Nm (10 lb.ft).

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Connect both EGR coolant cross-over pipe hoses.   Remove the EGR coolant hose clamps.

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Connect the low-pressure fuel lines.   Remove the blanking caps from the ports.

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Install the intake air shutoff throttle.

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Connect the battery ground cable.

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Check and top-up the engine oil.

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Check and top-up the coolant.

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Bleed the fuel system.