Replace Injector Return Fuel Line - Yanmar BY Series Service Manual

Repair
12/05
8. If removed, install fuel return hose fitting with
new seal washers. Tighten banjo bolt to 25 N·m
(221 in.-lb).
9. Install fuel rail on engine. Install and tighten
bolts.
10. Connect return hose and tighten clamp using
special socket.
11. Connect electrical connectors to fuel pressure
sensor and fuel pressure regulator.
12. Install high-pressure lines. See Remove and
Install High-Pressure Fuel Lines on page 6-14.
13. Install intake manifold. See Intake Manifold on
page 5-66.
14. Open all fuel supply valves.
15. Connect the battery negative (-) cable.
16. Bleed fuel system. See Bleed the Fuel System
on page 6-22.
17. Start engine and check for fuel leaks.

Replace Injector Return Fuel Line

1. Disconnect the battery negative (-) cable.
2. Shut off all valves in the fuel supply system.
3. Remove intake manifold. See Intake Manifold
on page 5-66. NOTICE: When working on the
oil, coolant or fuel systems, you must protect
the alternator against contamination. Cover
alternator with suitable materials.
4. Push clip (Figure 6-40, (1)) in direction of arrow
and remove fitting (Figure 6-40, (2)) from fuel
injector top. Repeat with all fuel injectors.
Figure 6-40
Figure 6-40
BY Service Manual
5. Disconnect return fuel hose (Figure 6-41, (1))
from fuel tee. NOTICE: NEVER disassemble
fuel return line assembly. No individual parts
are available and it must be replaced as a
complete assembly.
Figure 6-41
6. Inspect O-ring (Figure 6-42, (1)) on each fitting.
If any O-ring is damaged, the entire return fuel
line (Figure 6-42, (2)) must be replaced as an
assembly.
Figure 6-42
7. Assembly is in the reverse order from
disassembly.
8. Open all fuel supply valves.
© 2009 Yanmar Marine International
FUEL SYSTEM
( 1 )
Figure 6-41
Figure 6-42
0003688
6-21