:  Jul 20, 2004



  : 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.

  : 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.

  : Wait at least 30 seconds after the engine stops before commencing any repair to the high-pressure fuel injection system. Failure to follow this instruction may result in personal injury.

  : 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 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

  : 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.

  : 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.

  : 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 plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

. Disconnect the battery ground cable.

. Remove the engine cover.

. Disconnect the fuel temperature sensor electrical connector.



. Release the fuel temperature sensor locking tangs.



.
  : Always plug any open connections to prevent contamination.

Remove the fuel temperature sensor from the fuel return line.
  Position an absorbent cloth to collect fluid spillage.
  Discard the O-ring seal.
  Clean the seal contact area.
  Install a clean blanking plug to the fuel return line.




. To install, reverse the removal procedure.
  Clean the immediate area.