Fuel Injector
WARNING:
High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600bar (23,200psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
CAUTION:
PAY CLOSE ATTENTION TO THE FOLLOWING POINTS WHEN INSTALLING FUEL INJECTORS.
- Blow out injector recesses, clean again with non-woven cloth and then cover over. Fiber residues from non-woven cloth ARE NOT permissible.
- Carefully carry out a visual inspection of the sealing surfaces of the injector recesses.
- The length of the round brush can be adjusted and should be approximately 3mm for cleaning the seal seat. Optimal cleaning is achieved only if a brush with a flat surface is used. If necessary the surface of the brush can be ground flat on a grinding stone.
- ALWAYS replace the seals which seal off the injectors at the cylinder head to the combustion chamber. It is important that no grease gets onto the seal. Any impurities on the seal, on the sealing surfaces at the injector and cylinder head as a result of combustion residue or similar are absolutely impermissible.
- The screws attaching the injectors must always be replaced. The screws must screw in easily, if not, clean the threaded whole with an appropriate thread tap.
- The tip of the injector nozzle MUST NOT be cleaned with a wire brush. Use a non-woven cloth.
- Clean entire injector with a non-woven cloth.
- Fiber residues from a non-woven cloth are not permissible.
- Apply a thin film of special grease to the injector stems.
- Remove the pin in the nozzle holes with the extension.
| 1 - INJECTOR DRAIN TUBES |
| 2 - RETAINING CLIP |
| 3 - INJECTOR HIGH PRESSURE LINE |
| 4 - INJECTOR SEAL |
| 5 - FUEL INJECTOR |
| 6 - TENSIONING CLAW |
| 7 - SPECIAL TOOLS #8938 AND #8937 |
- Clean injectors (5) and recesses. See STANDARD PROCEDURE .
- Coat injector (5) body with anti seize lubricant and install injectors with new seals (4). See Fig 1.
- Install tensioning claw (6) with new fastener. See Fig 1. Torque in two stages, 7 N.m (62 in. lbs.) then 90°.NOTE: If drain tube locking clips have been removed from injectors, the clips must be replaced.
- Connect fuel drain tubes (1) at injectors (5). See Fig 1.
- Install high pressure fuel lines (3) from rail to injectors (5). See Fig 1. See INSTALLATION .
- Connect injector (5) electrical connectors.
- Connect negative battery cable.WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600bar (23,200psi). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
- Start engine and check for leaks.
- Install engine cover.