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 TM 5-1940-277-20
TM 1940-20/2
FUEL RETURN MANIFOLD AND RETURN TUBES REMOVAL
WARNING
Diesel fuel is flammable. Keep fuel away from open flames
and keep fire extinguisher within reach when working
with fuel. Do not work on fuel system while engine is hot.
Fuel can be ignited by contact with hot engine. Failure to
comply may result in death or injury to personnel.
CAUTION
Cap or plug all hoses, tubes, connections, and openings
immediately after disconnection to prevent contamination.
Remove caps or plugs prior to installation. Failure to do so
may result in damage to equipment.
NOTE
Have container ready to catch fuel.
1.
Using 3/8 inch wrench, remove six screws (1) and banjo seals (19) from fuel return manifold (2) and
fuel injectors (4). Discard banjo seals (19).
2.
Using 1/2 inch wrench, loosen nut (3) and remove fuel return manifold (2) from engine (5).
3.
Remove fitting (9) from fuel return tube (11) and fuel return hose (10).
4.
Using 1/2 inch wrench, loosen nut (7) on return tube (11) and tee remove from fitting (6).
5.
Using 3/8 inch wrench, remove screw (8), return tube (11), and rubber grommet (12) from
engine (5).
6.
Using 3/8 inch wrench, loosen nuts (14) and (17) on fuel return tube (16).
7.
Using 3/8 inch wrench, remove screw (13), fuel return tube (16), and rubber grommet (15) from
engine (5).
FUEL RETURN MANIFOLD AND RETURN TUBES INSTALLATION
1.
Install fuel return tube (16) on engine (5) with rubber grommet (15) and screw (13) using 3/8 inch
wrench.
2.
Connect fuel return tube (16) to tee fitting (6), and fuel injection pump (18). Tighten nuts (14)
and (17) using 3/8 inch wrench.
3.
Connect fuel return tube (11) to tee fitting (6). Tighten nut (7) using 1/2 inch wrench.
4.
Connect fitting (9) to fuel return tube (11) and return hose (10) using 3/8 inch wrench.
5.
Install fuel return tube (11) on engine (5) with rubber grommet (12) and screw (8) using 3/8 inch
wrench.
6.
Install fuel return manifold (2) on engine (5) and connect return manifold nuts (3) to tee fitting (6).
Tighten nut (3) using 1/2 inch wrench.
7.
Connect fuel return manifold (2) to six fuel injectors (4) with new banjo seals (19) and screws (1).
Tighten screws (1) to 11 lb-ft (15 Nm) using 3/8 inch wrench.
Change 2
3-262.3
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