| Rules for cleanliness and instructions for working on fuel system |
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| Clean tools and workbench etc. before working on the injection system. |
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| Thoroughly clean all unions 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. 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 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 the injectors are removed and installed: „copper seal“, „O-ring for injector bore“, „O-ring for injector 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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| Align the high-pressure fuel lines so they are free of tension. 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 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 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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