No 2. injector only

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. Injector 4: Using new sealing washers, fit spill return pipe to injector and tighten banjo bolt.
6. Injectors 2 and 3: Connect spill return pipe to injector.
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.

No 2. injector only

13. Clean mating faces of EGR recirculation pipe, inlet manifold and inlet manifold intake pipe.
14. Using new gasket, fit inlet manifold intake pipe and tighten bolts to 20 Nm.
15. Align EGR recirculation pipe to inlet manifold, fit bolts and tighten to 25 Nm.
16. Fit bolt securing inlet manifold intake pipe to camshaft cover and tighten to 9 Nm.

All injectors

17. Connect intercooler top hose to inlet manifold and tighten clip.
18. Position sound deadening pad and secure with bolts.
19. Connect battery earth lead.

INJECTION PUMP

Service repair no - 19.30.07

Remove

1. Disconnect battery earth lead.

2. Remove 3 bolts securing sound deadening pad to engine.
3. Remove sound deadening pad.
4. Remove injection pump timing belt. See MAINTENANCE.

5. Slacken injection pump shaft clamp bolt.
6. Remove spacer from clamp bolt.
7. Tighten clamp bolt to 12 Nm.

CAUTION: DO NOT exceed specified torque. damage to the injection pump shaft will render the pump inoperable.