| Instructions for working on fuel system |
| 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 fuel system components between fuel tank and fuel high-pressure pump are removed or replaced, initial fuel filling must be carried out. |
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| If a fuel pump, fuel pipe (between fuel tank and fuel high-pressure pump) or fuel filter is removed or renewed. |
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| Fuel system must be bled before starting engine for first time |
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| If a fuel pump, fuel line (between fuel tank and fuel high-pressure pump) or the fuel filter is removed or renewed, fuel system bleeding must be carried out before first starting engine. |
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| Clean tools and workbench etc. before working on injection system. |
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| Thoroughly clean all unions and adjacent areas before disconnecting. |
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| When removing components, seal 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 injectors and their surroundings visually; they must be undamaged and free of lint. Make sure the injector bores in the cylinder head are clean. Wipe out if necessary using a clean cloth, taking care not to cause damage. Do not use sharp objects of any kind. |
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| If high-pressure lines are not renewed, they must be labelled on removal. High-pressure fuel lines must always be re-installed in their original positions (i.e. on the same cylinder). |
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| The following components and seals/O-rings must always be renewed when injectors are removed and installed: „copper seal“, „O-ring for injector bore“, „injector return clip“„also to be used if necessary“„O-ring for injector return connection“„, injector seal“. |
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| The following components and seals/O-rings must renewed on renewing an injector: „ included in the scope of supply are “„copper seal“, „O-ring for injector bore“, „injector return clip“„also to be used if necessary“„O-ring for injector return line“„, injector seal“. |
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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. |
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| Take care not to damage the injectors when removing the old copper seals. |
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| Align high-pressure lines free from tension. First tighten all unions hand-tight and then tighten to torque. |
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| On high-pressure lines, tools may only be used for loosening or tightening. |
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| Never attempt to reshape high-pressure fuel lines. |
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| Disassembling individual common high-pressure accumulator components is not permitted. |
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| The components should be replaced as complete units if faulty. |
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| Never attempt to bleed the common high-pressure accumulator system by loosening high-pressure components after starting the engine. |
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| Do not carry out any installation work on common high-pressure accumulator system whilst engine is running. |
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| In particular, do not open or release high-pressure lines and electrical connectors. |
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| All cable ties which were opened or cut open during removal must be replaced in same position during installation. |
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| When the fuel system is open: Do not work with compressed air if this can be avoided. 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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