Injector needle lift sensor (page 2 of 2)

12. Disconnect spill return pipe from injector.
13. Remove bolt and collect clamp plate securing injector to cylinder head.
14. Remove injector from cylinder head, remove and discard sealing washer. Do not carry out further dismantling if component is removed for access only.
15. Remove spill return pipe banjo bolt and discard 2 sealing washer.
16. Using new sealing washers, fit spill return pipe to new injector and tighten banjo bolt.

Refit

1. Thoroughly clean injector and injector seat in cylinder head.
2. Fit new sealing washer to injector and fit injector to cylinder head.

CAUTION: Domed surface of sealing washer must face towards injector.

3. Fit clamp plate to injector, align injector and clamp plate to bolt hole in cylinder head.
4. Fit injector clamp plate bolt and tighten to 23 Nm.
5. Connect spill return pipe to injector.
6. Connect needle lift sensor multiplug to harness.
7. Remove plugs from injector pipe, injection pump and injector unions.
8. Clean injector pipe, injection pump and injector unions.
9. Position injector pipe to injection pump and injector, connect unions.
10. Align injector pipe to other injector pipes, fit and secure retaining clips.
11. Tighten injector pipe to injector union to 28 Nm.
12. Tighten injector pipe to injection pump union to 28 Nm.

CAUTION: To prevent damage to fuel system pipes or components, use 2 spanners when loosening or tightening unions.

13. Connect intercooler top hose to inlet manifold and tighten clip.
14. Position sound deadening pad and secure with bolts.
15. Connect battery earth lead.