Fuel system - Service procedures

7

Remove the pin screw for the injector’s yoke. Check that the screw on tool 8140 extrudes approx. 16 mm (0.63") from the tool.

8

Screw tight the tool in the copper sleeve. Remove the copper sleeve from the cylinder head. Remove the sealing ring.

Fit the pin screw for the injector’s yoke.

11

Oil in a new O-ring and place it in the cylinder head.

12

Push down the sleeve and tool in the cylinder head. Check that the sleeve’s indicating mark (recess) points straight up.

9

Clean the sealing surface between the cylinder head and the base of the copper sleeve. Tool 9812546 can be used for this purpose.

10

Unscrew the flare tap (1) from tool 6647. Unscrew the nut (2) for the tool’s spindle.

Place the new copper sleeve on the tool and screw in the flare tap.

Note! Grease the flare tap.

13

Tighten the flare tool with the injector’s yoke and nut until the copper sleeve reaches the base of the cylinder head.

14

Secure the tool’s spindle and screw down the large nut. The flare tap is then pressed through the lower section of the copper sleeve.

15

Screw down the nut until the tool’s spindle releases from the sleeve. Pull up the spindle and remove the rest of the tool from the cylinder head.

16

Put the steel ring on tool 6647 (without spindle and flare tap). Carefully drive the steel ring down with a plastic mallet.

17

Fit the injector (tightening torque: see Workshop Manual, Technical Data for each engine concerned). Connect the fuel pipe.

18

Fill with coolant.

Removal of sealing screw

Use tool no. 885346 as follows, to remove the sealing screw on the injection pump:

1

NOTE! The distance between steel ring and copper sleeve shall be 0.5 mm (0.02") . Check the distance with an angular feeler gauge.

Tighten the socket cap screw of the tool with an Allen key. 2

Put the tool on the top of the tapered thread on the sealing screw, and turn the tool anti-clockwise by hand until movement stops. Use a 17 mm spanner to undo the sealing screw.