| To prevent the high-pressure fuel pump from running while it is empty and to ensure that the engine starts quickly after parts have been renewed, it is important to observe the following: |
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| If components of the fuel system between the tank and the high-pressure fuel pump are removed or renewed, the basic setting „Checking fuel system pressurisation pump“ must be performed to bleed the fuel system. |
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| If a fuel pump, fuel line or fuel filter are removed or renewed, the basic setting „Checking fuel system pressurisation pump“ must be performed »ONCE« before the engine is started for the first time. |
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| If the high-pressure fuel pump is removed or renewed, the basic setting „Checking fuel system pressurisation pump“ must be performed »three times« before the engine is started for the first time. |
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| Clean tools and workbench etc. before working on the injection system. |
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| Thoroughly clean all connections and surrounding areas before disconnecting. |
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| When removing components, plug all open connections immediately with suitable clean sealing caps. |
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| Do not remove sealing caps from components until immediately prior to installation. After removal, components should be kept in new, sealable plastic bags (use the original new part packaging if possible). |
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| Before installation, check the injectors and their surroundings visually; they must be undamaged and free of lint. Ensure that the injector valve bore is clean. If required, clean the bore of the injector valve with a clean cloth; do not cause any damage in the process! (Do not use any sharp-edged tools!) |
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| When renewing a component, also renew all high-pressure fuel lines leading from the relevant component. |
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| If components are not being renewed, always mark the high-pressure fuel lines on removal. High-pressure fuel lines must always be re-installed in their original positions (cylinder). |
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| The following components and seals/O-rings must always be replaced when an injector valve is renewed: „copper seal“„O-ring of the injector valve bore“„O-ring on the injector valve return connection“ |
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| The following components and seals/O-rings must always be renewed when an injector is renewed: „clamping piece“, „injector pipe“, „copper seal“, „O-ring for injector bore“, „O-ring for injector return connection“. |
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| Always fit new copper seals for the injectors. Check all new O-rings for damage before installing. Lubricate O-rings lightly with assembly oil or clean engine oil before installing. Use assembly tool for installing the „O-ring for injector return connection“. |
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| Take care not to damage the injectors when removing the old copper seals. |
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| Install high-pressure pipes free of stress. Tighten all unions lightly to start with before tightening to final torque. |
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| Never attempt to reshape high-pressure fuel lines. |
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| When working on any parts of the high-pressure fuel system, tools may only be used for loosening and tightening pipe unions. The remaining installation and removal must be carried out by hand without any aids. |
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| Press the return lines onto the injectors by hand from above so that they engage audibly on each injector (do not press in the release pins when doing this). Then press down the release pin after connecting the return line. Check that the return lines are seated securely by pulling them by hand from above. Also check that they seal properly (fuel pressure in return line as far as pressure retention valve: between 8 and 10 bar). |
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| All cable ties which are opened or cut open when removing must be replaced in the same position when installing. |
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| When the fuel system is open: Do not use compressed air unless absolutely necessary. Do not move vehicle unless absolutely necessary. |
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| Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed. |
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