| Rules for cleanliness and instructions for working on fuel system |
| To prevent the high-pressure 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: |
Caution | Running when dry causes irreparable damage to high-pressure pump. |
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| If components of the fuel system between the fuel tank and the high-pressure pump are removed or renewed, the first fuel filling operation must be performed in order to bleed the fuel system. |
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| Performing first fuel filling after installing high-pressure pump → Chapter |
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| Clean tools and workbench etc. before working on the injection system. |
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| Carefully clean connection points and the surrounding area with engine cleaner or brake cleaner and dry thoroughly before opening. |
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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. Keep components that are to be re-used in new, sealable plastic bags. |
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| Before installing, check the injectors and their surroundings visually; they must be undamaged and clean. 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 the high-pressure fuel lines are to be re-used, you must mark them before removal. High-pressure pipes must always be re-installed on the same cylinder. |
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| Take care not to damage the injectors when removing the old copper seals. |
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| Check all new O-rings for damage before installing. Lubricate O-rings with engine oil or assembly oil before installing. |
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| Position high-pressure pipes so they are free of stress. Tighten all unions lightly to start with before tightening to final torque. |
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| Never attempt to bend high-pressure fuel lines to shape. |
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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. All other components must always be removed and installed by hand without using tools or other equipment. |
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| Press the fuel return hoses 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 fuel return hoses 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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| Do not dismantle individual common rail components. If there is a fault, the complete components must be renewed. |
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| When the engine is running, do not perform any repairs to the common rail system. |
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| Do not bleed the common rail system by unfastening high-pressure components after the engine has been started. |
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| All cable ties which are released or cut open when removing must be refitted in the same position when installing. |
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| When the fuel system is open: Do not work with compressed air if this can be avoided. Do not move the 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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