Injectors and fuel supply pipes, change

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1: Junction nipple 2: Copper washer 3: Nut on injector 4: Tension yoke 5: Screw

Removed cover and fuel filter bracket

Special tools: 885289, 9997008, 9997010

1. Removal of injectors and delivery pipes

Clean the area around injectors and the delivery pipe connections prior to removal.

WARNING! FIRE HAZARD. Be very careful to make sure that no sparks occur when working with the injection system.

Use paper to suck up any spilled fuel as work progresses.

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2. Remove the delivery pipes.

IMPORTANT! Only use the connecting nipple (1) as the counterhold for injectors.

IMPORTANT! The delivery pipes must not be re-used.

NOTE! If the delivery pipe between the high pressure pump and manifold has been removed, it must be replaced.

3. Remove: - The fuel return hose and the contacts from the injectors - The injectors. Remove the mounted injectors using tool 999 7008. NOTE! Make sure that copper washer (2) is not left in the cylinder head nozzle seat.

4. Clean the injector’s nozzle seats using brush 885289.

IMPORTANT! Make sure that the surface where the injectors reach the lower part against the cylinder head are thoroughly cleaned. No deposits are allowed.

Make sure that the tool end of the brush has been carefully cleaned. Use compressed air to blow the nozzle seat clean. Turn the brush a few times with the rod until the nozzle seat surface is completely free from soot. Blow clean from time to time and check cleanliness.

5. Refitting of injectors and delivery pipes

Fit new injectors and screw the tension braces down so much that the injectors still can be rotated slightly.

Use tool 999 7010 to place the injectors in the correct position. Torque the screws to 13 Nm.

IMPORTANT! When installing new or old injectors, you must use new tension yokes, copper washers and screws.

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6. Fit the new delivery pipes. Screw all cap nuts all the way down by hand.

7. Angle tightening of cap nuts

IMPORTANT! When torquing nuts to 40° - 60° angle, a torque wrench must be used, adjusted to 45 Nm. It is important that you do not exceed 45 Nm.

IMPORTANT! If the torque becomes too great before reaching the correct angle, the connection must be removed and lubricated with engine oil before it is torqued again. If the torque again exceeds 45 Nm, the delivery pipes must be replaced with new ones.

The nut is hexagonal and each corner is 60°.

Mark the pipe and one side of the nut using a pen as illustrated. The side of the nut is divided into three equal parts, which correspond to 20° each. NOTE! The mark should not be made until the nut has been torqued to 28 Nm.

When the line on the pipe faces the right section, the torque angle will be between 40° and 60°.

8. Torquing cap nuts

Torque all cap nuts (1-12) to 28 Nm.

Set torque wrench to 45 Nm and torque the cap nuts (1-7) to 40° - 60° angle. NOTE! Do not torque the cap nuts (8-12) using angle tightening.

Tightening torque must not not exceed 45 Nm, see step 7.

IMPORTANT! Place the return hose between cylinder 1 and 2 below the delivery pipe as shown in the picture.

10.Wipe clean and check the engine.

Re-install the fuel filter bracket and cover.

Bleed the fuel system, see ”Fuel system, bleeding.”

Test run the engine and check that there is no leakage.