Page 260 of 667
FUEL SYSTEM
5
DESCRIPTION AND OPERATION FUEL PRESSURE REGULATOR
NOTE: Non EU3 Model illustrated.
1.Gasket
2.Housing
3.Bolt
4.Fuel feed union and pipe
5.Fuel return union and hose
6.Fuel temperature sensor
7.Bonded seal8.’O’ring
9.Circlip
10.Fuel pressure regulator
11.’O’ring
12.’O’ring
13.Gauze filter
The fuel pressure regulator is located in a cast alloy housing which is attached to the rear right hand corner of the
cylinder head with three flanged bolts and sealed with a metal gasket. Two ports in the housing connect with ports
in the cylinder head for fuel pressure feed and return. A gauze filter is located in the pressure feed port in the
cylinder head, and filters the fuel before it reaches the injectors. The filter is a fit for life item but can be changed if
required. An’O’ring is located in a recess in the cylinder head and provides additional sealing for the pressure
feed port between the gauze filter, the cylinder head, and the housing.
A union and pipe is attached to the feed port in the housing and connects with a quick release coupling to the fuel
pressure feed pipe from the fuel pump. A second union and hose is located in the return port and provides the fuel
return connection to the fuel cooler. A third port provides location for the fuel temperature sensor, which is sealed
to the housing with a bonded seal. The fuel temperature sensor is used by the ECM for engine management.
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Page 264 of 667
FUEL SYSTEM
9
DESCRIPTION AND OPERATION FUEL FILTER
1.Filter body
2.Nut
3.Bolt
4.Rubber washer
5.Water sensor6.Filter element
7.Air bleed valve
8.Air bleed connection
9.Copper washer
10.Connector
The fuel filter is mounted on the chassis longitudinal below the rear RH wheel arch. The filter has four quick
release coupling connections; low pressure feed from the fuel pump, low pressure return to the fuel pump, return
line from the fuel pressure regulator and a bleed line to the fuel pump. The fuel filter removes particulate matter
from the fuel and also separates water which accumulates at the bottom of the filter.
An air bleed valve is located in the bleed line connection. The valve comprises a restrictor and a membrane. The
restrictor has a small hole in its centre. This allows air and fuel to pass through the membrane. Air can pass
through the membrane, but once the membrane is wet with fuel, it will not allow further fuel to pass through.
The fuel filter has a replaceable screw-on cannister type filter element which is sealed to the filter body with rubber
seals. The lower part of the cannister has a screw connection for a water sensor. The filter has a flow rate of 180
litres/hour (47.6 US Gallons/hour).
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Page 265 of 667
19FUEL SYSTEM
10
DESCRIPTION AND OPERATION WATER SENSOR
The water sensor has a three pin electrical connector. When the sensor detects water in the fuel filter it illuminates
a warning lamp in the instrument pack.
The water sensor attachment thread has a slot machined down one side. The filter can be purged of water by
partially unscrewing the sensor which aligns the slot in the threads with a corresponding hole in the sensor. When
aligned, water and fuel can flow down the slot and flows from a small cast tube on the side of the sensor.
Re-tightening the sensor mis-aligns the slot and stops the flow of fuel.
The sensor operates by measuring the resistance between its two electrodes, which are submerged in fuel, and
activated by the presence of water. When the ignition switch is moved to position’II’, the warning lamp will
illuminate for approximately 2 seconds to check warning lamp functionality.
When the filter is full with fuel and no water is present, the resistance of the Diesel fuel will show a reading of 15
mA maximum on the feed wire to the instrument pack. When sufficient water surrounds both electrodes, the
resistance of the water will show a reading of 130 mA maximum. This will supply sufficient voltage to the
instrument pack to illuminate the warning lamp, and alert the driver to the presence of water in the fuel system.
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Page 270 of 667
FUEL SYSTEM
1
REPAIR ELEMENT - AIR FILTER
Service repair no - 19.10.10
Remove
1.Release 2 clips and disconnect air flow meter
from air filter cover.
2.Disconnect multiplug from AAP sensor.
3.Release 2 clips and remove cover from air filter.
4.Remove air filter element.
Refit
5.Clean air filter body and cover.
6.Fit new air filter element.
7.Position air cleaner cover and secure clips.
8.Position air flow meter and secure clips.
9.Connect AAP sensor multiplug.SENSOR - FUEL TEMPERATURE
Service repair no - 19.22.08
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Release fixings and remove battery cover.
3.Disconnect battery negative lead.
4.Disconnect multiplug from fuel temperature
sensor.
5.Thoroughly clean area around fuel temperature
sensor before removal.
6.Remove fuel temperature sensor and discard
sealing washer.
Refit
7.Clean fuel temperature sensor mating faces.
8.Fit new sealing washer and tighten fuel
temperature sensor to13 Nm (9 lbf. ft).
9.Connect multiplug to fuel temperature sensor.
10.Reconnect battery negative lead.
11.Fit battery cover and secure fixings.
12.Fit engine acoustic cover and secure with bolts.
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Page 271 of 667
19FUEL SYSTEM
2
REPAIR SWITCH - INERTIA - FUEL CUT OFF
Service repair no - 19.22.09
Remove
1.Disconnect multiplug from fuel cut off switch.
2.Remove 2 screws securing switch to bulkhead.
3.Remove switch.
Refit
4.Position switch to bulkhead.
5.Fit screws securing switch to bulkhead.
6.Connect multiplug.
7.Press top of switch to set switch.SENSOR - MASS AIR FLOW (MAF)
Service repair no - 19.22.25
Remove
1.Disconnect multiplug from MAF sensor.
2.Loosen clip screw and release air intake hose
from MAF sensor.
3.Release 2 clips and remove sensor from air
cleaner.
Refit
4.Position sensor to air cleaner and secure clips.
5.Position air intake hose and tighten clip screw.
6.Connect multiplug.
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Page 272 of 667
FUEL SYSTEM
3
REPAIR SENSOR - COMBINED MAP AND IAT
Service repair no - 19.22.26
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Disconnect multiplug from combined MAP and
IAT sensor,
3.Remove 2 bolts securing sensor to inlet
manifold.
4.Remove sensor and discard’O’ring.
Refit
5.Clean sensor and mating face.
6.Fit new’O’ring and position sensor to manifold.
7.Fit and tighten MAF and IAT sensor bolts to9
Nm (7 lbf.ft)
8.Fit engine acoustic cover and secure with bolts.SENSOR - AMBIENT AIR PRESSURE (AAP)
Service repair no - 19.22.27
Remove
1.Disconnect multiplug from AAP sensor.
2.Remove 2 screws and remove sensor.
3.Remove and discard’O’ring.
Refit
4.Clean sensor and air cleaner cover.
5.Fit new’O’ring, fit sensor and tighten screws.
6.Connect multiplug to AAP sensor.
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Page 275 of 667
19FUEL SYSTEM
6
REPAIR Refit
17.Clean turbocharger and oil drain pipe mating
faces.
18.Using a NEW gasket, fit turbocharger drain pipe
and tighten bolts to10 Nm (7 lbf.ft).
19.Using a new gasket fit turbocharger to exhaust
manifold and tighten nuts to30 Nm (22 lbf. ft).
20.Position oil drain pipe to cylinder block and
tighten union.
21.Using new gasket, align exhaust front pipe and
tighten nuts to30 Nm (22 lbf.ft)
22.Fit banjo bolt to oil feed pipe using new sealing
washers and tighten to25 Nm (18 lbf.ft).
23.Position air outlet hose to turbocharger and
tighten clip screw.
24.Position and secure vacuum hose to
turbocharger wastegate.
25.Position exhaust manifold heat shield and
tighten M6 bolts to9 Nm (7 lbf.ft)and M8 bolt to
25 Nm (18 lbf.ft).
26.Position air inlet hose to turbocharger and
tighten clip screw.
27.Connect air flow meter to air filter and secure
clips.
28.Connect air flow meter multiplug.
29.Connect breather hose and secure clip.
30.Fit engine acoustic cover and secure with bolts.
31.Reconnect battery negative lead.
32.Fit battery cover.FILTER ASSEMBLY - AIR
Service repair no - 19.10.01
Remove
1.Loosen clip screw and release intake hose from
air filter.
2.Release 2 clips securing air flow meter.
3.Release air flow meter from air filter cover and
position aside.
4.Disconnect multiplug from AAP sensor.
5.Release air filter from 3 grommets, remove
assembly and discard’O’ring.
6.Remove 2 screws, remove AAP sensor and
discard’O’ring.
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Page 276 of 667
FUEL SYSTEM
7
REPAIR Refit
7.Clean air flow meter faces.
8.Fit new’O’ring to air filter.
9.Clean AAP sensor.
10.Using new’O’ring, fit AAP sensor and tighten
screws.
11.Position air filter assembly and secure in
grommets.
12.Position air flow meter and secure clips.
13.Position intake hose to air filter and tighten clip
screw.INJECTOR - SET
Service repair no - 19.60.12
Remove
1.Remove cooling fan.See COOLING SYSTEM,
Repair.
2.Remove rocker shaft.See ENGINE , Repair.
3.Position container to catch fuel spillage.
4.Disconnect quick release fuel hose connectors
from fuel connector block on cylinder head and
fuel cooler to drain fuel from cylinder head.
5.Disconnect 5 multiplugs from injectors.
6.Remove Torx bolt securing injector unit to
cylinder head.
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