Thread: TD5 - Replacing return fuel line - injectors to FPR

crows foot spanner maybe, or remove the inlet manifold. With that off you should be able to get it with an open ended spanner.

Originally Posted by Psimpson7

crows foot spanner maybe, or remove the inlet manifold. With that off you should be able to get it with an open ended spanner.

I found it easiest to remove the inlet manifold.

thats my approach as well.

Thanks guys!!!
I have obtained a crows foot wrench, and it is pouring down so it will have to wait til tomorrow evening!!!
I am finding everything either difficult to get to or exceedingly tight!!
The bolt holding the fuel return bracket and alternator wont budge, and to ease the access I need to remove the EGR from the front. Top bolt okay, but bottom one means I need to remove the fan ~ what size is the A/F of the fan nut and is it a Left or right hand thread?
I am hesitant to remove the inlet manifold as I am struggling to gain access to all the 8 bolts and two nuts! so will attempt to remove the nut from the front with crows foot wrench, and then hopefully the stubborn bolt on the bracket!!

Thanks again!

Giles

The Viscous fan is a Normal thread, not left hand. From memory it is 36mm

You should be able to get it off with a decent whack from a mallet/hammer on the end of the spanner even without the tool to hold the hub still.

Okay I admit defeat ~ crows foot spanner wont quit access the nut on the front connection of the the return fuel line, so I must remove the inlet manifold!

I have an EG3 type 2 EGR system, which means I have to remove the EGR cooler from the front of the block, which means I have to remove the fan.

If I just remove the EGR valve from the manifold and this gives me space without removing the EGR cooler ~ what happens if I remove the pipe between the EGR Valve and EGR cooler, I am concerned as I read somewhere that the EGR cooler should be removed from the exhaust manifold and not at the cooler, plus the allen bolts (shcs) should be replaced ~ what size?

plan of attack is now to order up the inlet manifold gasket and the EGR valve gasket,
remove the EGR valve and then if I still do not have enough access to the nut holding the fuel return line, then remove the inlet manifold.

any advice greatfully received.

thanks again,

Giles

Giles,

Most recommendations I think you'll get will be to remove the EGR and fit blanking plates.

You can do a complete removal or part there of. Most tend to use blanking plates on the exhaust manifold and replace the valve/pipe with a pipe with no valve. There are a stack of kits available.

The cheapest would be to use a blanking plate on the exhaust manifold and remove the butterfly from the EGR valve. A bit more fiddley to remove the butterfly but cheaper.

IF you remove the EGR cooler from the front of the timing case permanently, 2 of the bolts holding it on go through into the timing chain cavity, if you don't refit the bolts (preferrably with thread sealant) there will be another Exxon oil disaster....

JC