Clean Working Conditions

Clean Working Conditions

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

• Always clean the connection locations and the area around them before loosening.

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

• Remove the caps from any components just before installing the component. Seal any removed components in a new, sealable plastic bags (re-use the original packaging from the new component if possible).

• Make sure the injectors and installation locations are not damaged and are free of lint before installing. Always make sure the injector shaft is clean. Clean the shaft with a clean cloth if necessary; do not use any sharp-edged tools!).

• If the high pressure lines will not be replaced, mark them when removing. High pressure lines may be installed only on the same location (cylinder).

• 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 at the top of the return lines to make sure they are seated securely and are not leaking. The fuel pressure in the return must be between 8 and 10 bar up to the check valve.

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

• Whenever the fuel system is open: avoid working with compressed air if possible. Do not move vehicle unless absolutely necessary.

• In addition, do not let diesel fuel flow onto coolant hoses. If necessary, the hoses must be cleaned again immediately. Replace corroded hoses.