Injector, replacing

Op nbr 23704

Tool:

1. Park the machine in the service position.

2. Turn off the electric power with the battery disconnect switch.

Figure 1

3. Raise engine covers (1)

Figure 2
 Removing

4. Disconnect cables (1) from the preheating element. Unscrew four bolts (2) for the induction manifold at the
preheating element.

Figure 3

5. Remove cover (2) from the air cleaner and ejector hose (1) from the silencer. Remove hose (3) from the oil
trap.

Figure 4

6. Remove the valve cover.

Figure 5
7. Remove fuel pipe (1) between the unit pump and the injector.

Figure 6

Note
Replace the fuel pipe every time it has been removed.

Note
Pay attention to the straightness.

8. Plug the connection by the pump unit.

9. Remove nozzle holder (2). Use Torx E10 (1).

Figure 7

10. Remove the injector by pulling it upwards:

Note
The sealing washer installed at the lower end of the injector should always be replaced.

11. Clean the injector location in the cylinder head before installing the injector.
 Installing

12. Fix copper washer (1) to the injector with a little grease.

Figure 8

13. Install the injector.

Note
Install the injector with the drilled hole turned towards the valve springs.

Figure 9

14. Install retainer (2) and torque-tighten bolt (1). Use Torx E10. Tightening torque: 16 Nm ((12 lbf ft).

Figure 10

15. Remove the plug on the unit pump.

16. Install the fuel pipe and tighten the union nuts. Tightening torque: 40-50 Nm (30-37 lbf ft)
 Note
It is not permissible to bend the pipe.

Figure 11

17. Install the valve cover together with a new gasket and torque-tighten the bolts. Tightening torque: 9 Nm (6.6 lbf
ft)

18. Install ejector hose (1) to the silencer and cover (2) on the air cleaner. Install hose (3) to the oil trap.

Figure 12

19. Install the preheating element using bolts (2) and connect electrical cables (1).

Note
Always use a new gasket for the preheating element.

Figure 13

20. Turn on the current with the battery disconnect switch. Start the engine and check that there are no faults.
21. Close down the engine covers.

Figure 14