Clean Working Conditions and Fuel System Work Instructions

Clean Working Conditions and Fuel System Work Instructions

• Place removed parts on a clean surface and cover them using lint free cloths.

• Carefully cover or seal unpacked components, if repairs cannot be performed immediately.

• Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored loose (for example, in a tool box, etc.).

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

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

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

• Remove the plugs from any components just before installing 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 too.

• Do not replace any components, mark the high pressure lines when removing them. High pressure lines may only be reinstalled to the same location (cylinder).

• The following components, seals and/or O-rings must be replaced each time the injectors are removed and installed: "Copper washer" "injector shaft O-ring" "injector return O-ring".

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

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

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

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

• Never bend the high pressure lines.

• It is permitted to use tools only for tightening and loosening the lines in 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 center piece). Then press the center piece downward. Check the return lines by pulling upward by hand for secure seating and for leaks.