Reconditioning

- clamp upper part of injector in vise and loosen lower section

- clamp lower part of injector when disassembling to avoid separation of parts





NOTE: When disassembling injectors care must be taken to avoid interchanging parts.

- tightening torque for upper and lower injector assembly is: 70 Nm (52 ft lb)

- visually check the fuel injectors for the following defects:
- needle seat worn out or rough
- damaged injector pin or build up of carbon
- out-of-round spray drilling
- tempering colors on nozzle body
- grooves on needle

NOTE: Worn or damaged needles must be replaced.





NOTE: Clean and visually check nozzle before starting float test. Submerge needle completely into clean diesel fuel and insert needle fully into nozzle body. Pull needle 213 out of nozzle body. Needle must float free under its own weight, back to the needle seat. If not replace complete nozzle (nozzle body and needle are a matched set).

- check injector for spray pressure and leakage

CAUTION: Diesel will penetrate skin if hands are exposed to working pressure of injector spray.

Spray Pressure Check
- slowly push hand lever downwards at beginning of spraying, read spray pressure and if necessary correct by exchanging the shim
^ specification - with new injector 155 - 163 bar (2248 to 2364 psi) wear tolerance - 140 bar (2031 psi)
- thicker shim increases pressure
- thinner shim decreases pressure
- increasing thickness by 0.05mm (0.002 in.) will increase the pressure by approximately 5.0 bar (71 psi)
- shims are available from 1.00 to 1.95mm (0.039 to 0.077 in.) thickness in steps of 0.05mm (0.002 in.)

NOTE: When repairing worn injectors, the pressure must be readjusted.

Leak Check
- press pump lever down slowly hold pressure at approximately 110 bar (1595 psi) for 10 seconds
- fuel should not drip from injector at nozzle