Clean Working Conditions and Fuel System Work Instructions

Clean Working Conditions and Fuel System Work Instructions

• Place parts that have been removed on a clean surface and cover them. Use lint free cloths.

• Carefully cover or seal opened components, if repairs are not performed immediately.

• Install only clean parts: remove the replacement parts from their packaging just before installing them. Do not use parts that have been stored loose (for example, in tool boxes, etc.).

• Clean the working area and tools before working on the injection system.

• Thoroughly clean all connections and the surrounding area before disconnecting.

• When disassembling, always cover any open connections immediately with clean caps.

• Remove the caps from any components just before reinstalling the component. Keep removed components in new, sealable packaging. Use plastic bags or wooden crates and the original packaging for the new components, if possible. Do not store them in cartons.

• Make sure the injectors and installed locations are not damaged and are free of lint before installing. Make sure the injector shaft is clean. Clean the injector shaft with a clean cloth if necessary without damaging it. Do not use any sharp edged tools.

• When replacing a component, always replace all of the high pressure lines that lead away from it also.

• Mark any high pressure lines when removing. High pressure lines may be reinstalled only on the same location (cylinder).

• The following components, seals and O-rings must be replaced each time a fuel injector is removed, and installed or replaced: "copper washer", "O-ring for the fuel injector shaft" and the "O-ring for the fuel injector return"

• The following components, seals and/or O-rings must be replaced each time an injector is replaced:"tensioning bracket" "injection line" "copper washer" "injector shaft O-ring" "injector return O-ring"

• Always use new copper seals for the injectors. Check all new O-rings for damage before installing. The O-rings must be lubricated for installation (use assembly oil or clean engine oil).

• Be careful not to damage the injector when removing the old copper seal.

• Align the high pressure lines so that they are free of tension. First tighten all the connections by hand and then tighten them to the specification.

• Never bend the high pressure lines.

• It is permitted to use tools only for tightening and loosening the lines on the entire high pressure system. All other installation or removal procedures must be performed by hand without using any tools.

• Press the return lines onto the injectors by hand and from the top until it audibly locks onto each injector (when doing this, do not press the release screw). Then press the release screw downward. Pull upward on the return lines to make sure they are secure and do not leak. The fuel pressure in the return line must be between 8 and 10 bar up to the check valve.