03:14-10

Issue 1.0 en-GB

HPI fuel system

Troubleshooting

©
Scania CV AB 2015, Sweden
Contents

Contents
HPI fuel system Introduction .............................................................. 3

Troubleshooting Before starting troubleshooting ................................ 4

A – The engine is difficult to start, cannot be
started at all, runs poorly or runs with loss of
power ........................................................................ 5
A – Instructions ........................................................ 6
B – White smoke after start ...................................... 7
B – Instructions......................................................... 8
C – Engine is difficult to switch off ......................... 9
C – Instructions....................................................... 10
D – The engine is difficult to start after a long
period of downtime................................................. 10

Checks Checking the fuel pressure in the valve housing .... 11

Checking the fuel pressure in the fuel filter
housing ................................................................... 12
Checking air in the fuel .......................................... 13
Checking the unit injector gaskets and sealing
plugs ....................................................................... 14
Cleaning the unit injector seat in the cylinder
head......................................................................... 16
Checking blocked fuel filter ................................... 18
Checking the fuel shut-off valve ............................ 20
Cleaning the overflow valve................................... 22
Checking the drainage of the fuel filter housing .... 23
Checking the feed pump......................................... 24
Checking the fuel tank ventilating valve ................ 24
Checking the unit injector check valve .................. 25
Checking the fuel pick-up unit check valve ........... 27
Checking the internal parts of the unit injector ...... 28
Overhaul of unit injectors....................................... 29
External cleaning and leak test of unit injector ...... 32
Dismantling and cleaning the component parts
of the unit injector .................................................. 32
Renewing the unit injector check valve.................. 37
Checking the injection nozzle wear and spray
pattern ..................................................................... 38
Assembling unit injectors ....................................... 41

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 HPI fuel system

HPI fuel system

Introduction
The fuel system is divided into 2 parts: the
high pressure section- and low pressure
section.
The purpose of the low pressure section is to
supply fuel from the fuel tank to the solenoid
valves, which in turn supply fuel to the unit
injectors. This fuel should be free from air and
have the correct pressure. These are
2 important conditions and should be checked
first when troubleshooting.
The aim of the high pressure section is to build
the correct injection pressure, which takes
place inside the unit injector.
The troubleshooting diagram in this document
is to be used as a guide for practical
troubleshooting. It is important to carry out a
system check before starting the
troubleshooting, refer to Before starting
troubleshooting.

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Troubleshooting

Troubleshooting

Before starting
troubleshooting
1 Check that there is fuel in the tank.
2 Check the fuel quality with regard to
viscosity, water content, contaminants and
wrong type of fuel.
3 Check that there are no visible leaks from
the fuel system.
4 Check any fault codes using SDP3 and
rectify them.

Note: SDP3 cannot detect an error in an

individual unit injector.

Note: During repairs or when the fuel system

is opened, air will always enter the system.
This typically causes vibrations and jerky
operation. Therefore, the system should always
be bled after rectification. Drive the vehicle or
let the engine idle for a longer time until there
is no air left in the system. This can take up to
20 minutes.

Each troubleshooting diagram comes with

instructions.

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 Troubleshooting

A – The engine is difficult to start, cannot be started at

all, runs poorly or runs with loss of power
Start the engine or drive it with the starter motor and carry out the following checks.

Check the fuel pressure of the valve housing using

SDP3. See page 11.

The fuel pressure The fuel pressure is

is incorrect correct
See the instructions in A1.

Check the fuel pressure in the

fuel filter housing, see
page 12.

The fuel pressure The fuel pressure

is incorrect is correct See the instructions in A2.

Cut the power to the fuel shut-off valve and

check the pressure in the fuel filter housing
again.

The fuel pressure The fuel pressure is

is incorrect correct

See the instructions in A3.

See the instructions in A4.

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Troubleshooting

A – Instructions
A1 – The fuel pressure in the valve housing
is correct
1 Check for air in the fuel system. See
page 13.
2 Check the valve clearances and the injector
closing force. Refer to section 03-01
Injection pump and injectors in the
Workshop Manual.
3 Check the injector gaskets and seat in the
cylinder head. See pages 14 and 16.
A2 – The fuel pressure in the fuel filter
housing is correct
1 Check whether the fuel filter is clogged.
See page 18.
2 Check that the fuel shut-off valve opens.
See page 20.
A3 – The fuel pressure in the fuel filter
housing is correct after the power to the fuel
shut-off valve has been cut off
1 Clean the overflow valves in the valve
housing. See page 22.
A4 – The fuel pressure in the fuel filter
housing is incorrect
1 Check the drainage of the fuel filter
housing. See page 23.
2 Clean the overflow valve in the fuel filter
housing. See page 22.
3 Check the feed pump. See page 24.

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 Troubleshooting

B – White smoke after start

Note: Check for paraffin precipitation in the fuel when the temperature drops below -5°C.

Note: If the tank is overfilled, white smoke can occur in the exhaust fumes. Fill the tank according to
the instructions in the Driver's Manual.

Check the fuel tank ventilating valve. See

page 24.

The ventilating valve The ventilating valve

works properly is faulty
See the instructions in B1.

Remove the exhaust manifold and start the

engine.

White smoke from all White smoke from the

cylinders front or rear cylinder
bank

See the instructions in B2.

See the instructions in B3.

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Troubleshooting

B – Instructions
B1 – The ventilating valve is faulty
1 Renew the ventilating valve.
B2 – White smoke from the front or rear
cylinder bank
1 Switch the timing solenoid valves between
the front and rear cylinder bank. Refer to
section 03-01 Injection pump and injectors
in the Workshop Manual.
2 If the fault is in the solenoid valve, renew
it.
B3 – White smoke from all cylinders
1 Search for the fault outside the fuel system.

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 Troubleshooting

C – Engine is difficult to switch off

Check the injector for leaks. See page 14.

No leaks Leakage

See the instructions in C1.

Check the injector check valve. See

page 25.

No leaks Leakage
See the instructions in C3.

See the instructions in C2.

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Troubleshooting

C – Instructions
C1 – Leakage
1 Check the injector sealing plugs. See
page 15.
C2 – No leaks
1 Search for the fault outside the fuel system.
C3 – Leakage after checking check valve
1 Recondition the injector. See pages 28-43.

D – The engine is difficult

to start after a long period
of downtime
1 Check the the fuel pick-up unit check
valve. See page 27.

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 Checks

Checks
Checking the fuel pressure in the valve housing

IMPORTANT! Do not run the starter motor for Diagram 1

more than 20 seconds at a time.

Start the engine or crank it with the starter

motor.
Carry out a fuel pressure check in the valve
housing using SDP3. Compare the result with
Diagram 1 or 2. If the supply pressure is
between the upper and lower limit, no fault
code is generated, which means that the fuel
pressure is acceptable.

System with 14.5 bar supply pressure.

A – Upper limit for supply pressure.
B – Lower limit for supply pressure at 45°C.

Diagram 2

System with 17 bar supply pressure.

A – Upper limit for supply pressure.
B – Lower limit for supply pressure at 45°C.

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Checks

Checking the fuel pressure in the fuel filter housing

IMPORTANT! Do not run the starter motor

for more than 20 seconds at a time.

Start the engine or crank it with the starter

motor.
Connect pressure gauge 99 362 to the bleed
nipple on the fuel filter housing. Check the fuel
pressure and compare with the measurement
from SDP3 and Diagram 1 or 2 on the previous
page. Also refer to subgroup 03-00 HPI fuel
system in the Workshop Manual.

Note: Pressure gauge 99 362 measures

overpressure. The pressure gauge in the valve
housing measures the absolute pressure (read
using SDP3). The absolute pressure will be
1 bar higher than the overpressure.

Note: Pressure gauge 99 362 measures the

pressure before the fuel filter. At higher engine
speeds, the pressure can be 1 bar higher before
the filter than after it due to normal flow
resistance.

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 Checks

Checking air in the fuel

1 Attach a transparent plastic hose to the fuel

filter bleed nipple. The hose should seal
tightly against the nipple. The other hose
end should lead back to the fuel tank or a
suitable vessel. Make sure that the hose
end is below the fuel surface.
2 Start the engine.
3 Open the bleed nipple slightly so that fuel
flows through the plastic hose. The small
flow in the hose does not affect the engine
operation.
4 Check if air bubbles are visible in the fuel
through the plastic hose. If there is any air
in the fuel, there will be leaks on the
suction side. Repair the leak.
5 Close the ventilating valve and switch off

B 119 292
the engine.

Note: When the engine is stopped, there will

be an overpressure in the part of the system
that is positioned between the fuel shut-off
valve and the fuel pick-up unit. This is why
any leaks can be seen during a visual check.

6 Remove the transparent hose.

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Checks

Checking the unit injector gaskets and sealing plugs

For removing the unit injector from the engine. Refer to section 03-01 Injection pump and injectors
in the Workshop Manual.

IMPORTANT! Remember to always lubricate

the unit injector at the bottom of the pushrod
and at the upper piston with engine oil when
replacing it or fitting a new injector. This
makes sure the injector is lubricated right from
the start.

Checking gaskets
A leaking injector has a problem with one of
the following:
• If the copper gasket B and the bottom
O-ring A are damaged, compression gas
can leak into the duct for fuel for
combustion.
• Fuel for combustion can also leak over
into the return side of the unit injector. If
the bottom O-ring is burnt this is a sign of
compression gas leaking past the copper
gasket.
The abovementioned leakage can also occur if
the check valve C in the injector is damaged.
Refer to the section Checking the unit injector
check valve.

Note: Always renew-O-rings and the copper

gasket.

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 Checks

One method of checking which injector is

causing the problem is to remove the fuel
manifold and crank the engine by hand. Check
at the same time if compression gas and fuel
are leaking back through any of the fuel ducts
in the cylinder head. Start by checking the unit
injector in this cylinder.

The cylinder head fuel ducts.

Checking the sealing plugs

If any of the sealing plugs D comes loose from
the injection nozzle, compression gas may leak
into the duct for fuel for combustion. Renew
the injector.

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Checks

Cleaning the unit injector

seat in the cylinder head
If deposits have formed on the unit injector
seat in the cylinder head, clean the bottom
sealing surface as specified below. Parts used to fabricate the tool:
• Emery cloth. Size 158 x 224 mm in one of
IMPORTANT! This cleaning procedure must the following grain sizes:
only be carried out when absolutely necessary.
There is a risk of dirt entering the fuel ducts. • CF-HP S UFN GRIS 07448
• CF-SH S UFN 7448
• CF-HP A VFN ROUGE 07447
A tool must be made to clean the unit injector
seat in the cylinder head. See the list of • Mandrel 933M. Length 75 mm. Shaft
supplies at the end of this document. 6.35 mm
• Hard plastic hose. Inner diameter 6 mm
and length 250 mm.
1 Glue the spindle in the hard plastic hose
with a suitable glue. • Plastic film. Size 120 x 300 mm.

2 Cut a 52 x 225 mm emery cloth strip from

a sheet with a suitable grain size.

3 Attach the strip to the spindle.

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 Checks

4 Roll the strip around the spindle.

5 Cut a protection sleeve from plastic film.
Dimension: 120 x 300 mm.

6 Roll the plastic film up so that it can be

moved down into the cylinder head.

IMPORTANT! The plastic film is intended to

protect the fuel ducts in the cylinder head when
cleaning.

7 Insert the tool into the cylinder head and

machine the unit injector seat.
8 Lift the tool with care and make sure the
plastic film is still in the cylinder head.
9 Replace the emery cloth with a lint-free
cloth moistened with fuel, and clean the
unit injector seat in the cylinder head.
10 Remove the tool.
11 Vacuum the seat.
12 Remove the plastic film.

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Checks

Checking blocked fuel

filter

Note: The fuel filter must not be confused with

the similar filter in the PDE-system. Check the
part number before fitting.

Note: Remove all protective plastic sheeting

from a new fuel filter before fitting it.

1 Connect SDP3.
2 Connect pressure gauge 99 362 to the
bleed nipple on the fuel filter housing.
Refer to subgroup 03-00 HPI fuel system
in the Workshop Manual.

Note: Pressure gauge 99 362 will measure

overpressure. The pressure gauge in the valve
housing measures the absolute pressure (read
using SDP3). The absolute pressure will be
1 bar higher than the overpressure.

Note: Pressure gauge 99 362 measures the

pressure before the fuel filter. At higher engine
speeds, the pressure can be 1 bar higher before
the filter than after it due to normal flow
resistance.

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 Checks

The following check can be made in 2 ways

depending on whether the engine can be started
or not.
If the engine cannot be started:

IMPORTANT! Do not run the starter motor

for more than 20 seconds at a time.

1 Drive the engine using the starter motor.

2 Measure the fuel pressure at the fuel filter
housing using tool 99 362 and at the valve
housing using SDP3. If the fuel pressure is
about 25 bar at the fuel filter and about
0 bar at the valve housing, the fuel filter is
probably blocked. Renew the fuel filter.
Refer to section 03-05 Fuel filter in the
Workshop Manual.

Note: It may also be due to the fuel shut-off

valve not opening. Refer to the section on
Checking the fuel shut-off valve.

If the engine can be started:

1 Start the engine.
2 Measure the fuel pressure at the fuel filter
housing using tool 99 362 at 1,500 rpm. If
the pressure is greater than 25 bar before
the fuel filter, the filter is probably
blocked. Renew the fuel filter. Refer to
section 03-05 Fuel filter in the Workshop
Manual.

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Checks

Checking the fuel shut-off

valve
Check the fuel shut-off valve using SDP3. If
there are active fault codes, follow the
instructions in SDP3.
1 Connect SDP3.
2 Connect pressure gauge 99 362 to the
bleed nipple on the fuel filter housing.
Refer to subgroup 03-00 HPI fuel system
in the Workshop Manual.
3 Turn the engine over using the starter
motor.

Note: Pressure gauge 99 362 will measure

overpressure. The pressure gauge in the valve
housing measures the absolute pressure (read
using SDP3). The absolute pressure will be
1 bar higher than the overpressure.

Note: Pressure gauge 99 362 measures the

pressure before the fuel filter. At higher engine
speeds, the pressure can be 1 bar higher before
the filter than after it due to normal flow
resistance.

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 Checks

4 Compare the pressure in the valve housing

with the pressure in the fuel filter housing.
If the pressure in the valve housing is too
low (below 10 bar) and the pressure in the
filter housing is correct (about 12 to
17 bar), the fuel shut-off valve will
probably not open. Clean the fuel shut-off
valve and renew if necessary.

IMPORTANT! Turn washer A the right way

round. If the washer is turned the wrong way, it
can be difficult to start the engine.

Note: The fault can also be due to the overflow

valve in the valve housing being stuck in the
open position.

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Checks

Cleaning the overflow

valve
1 Remove the overflow valve from the fuel
filter housing or the valve housing.

Note: On the inside of the fuel filter housing

overflow valve there is a strainer that should be
cleaned.

The strainer must also be cleaned.

2 Secure the overflow valve in a vice.

3 Open the overflow valve by pressing the
piston down with a screwdriver. Blow the
valve clean with compressed air.

Note: Always renew the overflow valve

gaskets when fitting an overflow valve.

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 Checks

Checking the drainage of

the fuel filter housing
1 Check the fuel filter seal against the centre
tube A and the bottom of the fuel filter
housing B.
2 Check that the automatic drainage of the
fuel filter housing is working. The fuel
filter housing will be automatically drained
of fuel when the filter is removed.

Note: On some vehicles, the filter housing has

to be drained manually via a valve at the
bottom.

IMPORTANT! On vehicles where the

automatic drainage or the manual drainage
does not work, the filter housing has to be
drained. Otherwise, unfiltered fuel may enter
the fuel system high-pressure section.

3 If the shaft seal appears to be intact, the

filter housing centre tube C should be
checked. Unscrew the centre tube and
check the sealing surface against the fuel
filter shaft seal. Search for cracks in the
tube and check the O-ring D.
4 Screw the centre tube back into place,
torque tighten to 10 Nm.
5 Fit a new fuel filter.

Note: The fuel filter must not be confused with

the similar filter in the PDE-system. Check the
part number before fitting.

Note: Remove all protective plastic sheeting

from a new fuel filter before fitting it.

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Checks
Checking the feed pump
1 Open the ventilating valve on the fuel filter
housing. Crank with the starter motor and
check that fuel comes out.
2 If fuel fails to flow: Check that the feed
pump is rotating.
3 If the feed pump does not rotate: Check the
connection between the feed pump and the
compressor, and between the compressor
and the engine.
4 If the feed pump rotates: Detach the
2 suction pipes from the feed pump. Plug
the lower connection of the feed pump.
Connect a temporary line from the upper
connection and down to the fuel tank.
5 Run the starter motor for about 20 seconds.
Check the fuel flow from the opened bleed
nipple. If no fuel comes out, the feed pump
must be renewed.
6 If fuel comes out of the bleed nipple: Close
the bleed nipple and try to start the engine.
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Scania CV AB 2015, Sweden
7 If the engine does not start: Check the
fuel pressures according to Checking the
fuel pressure in the valve housing and
Checking the fuel pressure in the fuel filter
housing. If the fuel pressure is too low, the
feed pump must be renewed.
8 If the engine starts: The fault is located
between the feed pump and the fuel tank.
Check the suction pipes and the fuel pick-
up unit according to the section Checking
the fuel pick-up check valve.
Checking the fuel tank
ventilating valve
1 Remove the ventilating valve and turn it
forwards and backwards. The float should
be moving freely in the valve.
2 Keep the ventilating valve in the same
position as when it is assembled on the
vehicle and blow compressed air in the
hose connection. If the float does not move
freely or if the valve is clogged, the
ventilating valve must be renewed.
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 Checks

Checking the unit injector

check valve
A tool must be made to check the integrity of
the check valve in the unit injector. A pressure
regulator, a shut-off valve, 2 hose couplings,
hose clamps and rubber hose 326 627 for
connection to the injector are needed.
Assemble the parts as illustrated. It is vital that
all couplings and connections are tight.
The tool is used to measure the pressure drop
over the check valve by measuring the time it
takes for the pressure to drop between
2 specific levels. C
1 Fit the injector on rubber hose 326 627
using a hose clamp.
2 Connect compressed air to the other side of
the pressure regulator.
3 Adjust the pressure regulator to 3 bar.
B
4 Check that there is no leakage in any joints
or connections to the injector. Use Scania
leak detector 584 018. A

352 507
A – Shut-off valve
B - Pressure regulator
C – Rubber hose 326 627 for connection to
injector

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Checks

5 Shut off the air with the shut-off valve and

measure the time it takes for the pressure
to drop from 3 bar to 2 bar. A functioning
check valve can hold the pressure for at
least 30 seconds.
If required:
Renew the check valve and the sealing washer,
refer to the section Overhaul of unit injectors,
Renewing the unit injector check valve.

IMPORTANT! Always lubricate the unit

injector at the bottom of the pushrod and at the
upper piston with engine oil when replacing it
or fitting a new injector. This makes sure the
injector is lubricated right from the start.

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 Checks

Checking the fuel pick-up

check valve
A tool must be made to determine whether the
check valve in the fuel pick-up unit is leaking.
A pressure regulator, a shut-off valve, 2 hose
couplings, a piece of rubber hose and a hose
clamp are needed. Assemble the parts as
illustrated. Check that the tool connections are
sealed. Use Scania leak detector 584 018.
1 Remove the tank filler cap. If the vehicle
has 2 tanks, also remove the filler cap on
the other tank.

A – Shut-off valve
B - Pressure regulator
C – Rubber hose for connection to the bleed
nipple of the fuel filter housing

2 Connect the rubber hose of the tool to the

bleed nipple on the fuel filter housing.
Attach the hose with a hose clamp.

IMPORTANT! The fuel system must not be

pressurised to more than 3 bar.

3 Open the bleed nipple and pressurise the

system to a max. of 3 bar. After about
10 minutes: Listen for a bubbling noise
from the tank where the fuel pick-up unit is
located. If a bubbling sound can be heard
the there is a leak in the check valve and
the tank pick-up unit must be renewed.
Refer to section 03-20 Fuel pick-up unit in
the Workshop Manual.

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Checks

Checking the internal The return springs

parts of the unit injector
The faults below can be checked when
dismantling the unit injector. For instructions
on dismantling the unit injector, refer to
Dismantling unit injectors.
Cylinder housing and pistons
Typical faults on a unit injector are a worn
cylinder housing, a worn upper piston or centre
piston (the yellow or black surface coating of
the piston is worn through).
There are 2 return springs in the injector. One
upper and one lower. In case they break they
may cause vibrations or continued operation
when the engine is stopped. A cylinder that has
an injector with broken springs will misfire.
One method of finding this fault is to remove
the exhaust manifolds and run the engine at
low rotational speed. Listen out for which
cylinder misfires.

Note: There may be unit injectors whose

pistons have differently-coloured surfaces in
the same engine.

The symptoms are reduced power and smoke

from the exhaust, but it should be pointed out
that the symptoms in most cases are not that
clear. When the wear has become considerable,
the timing of the injection, α° (alpha), is
delayed and too little fuel is injected. In these
circumstances, the injector cannot be repaired.

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 Checks

Overhaul of unit injectors Special tools

When working with the unit injectors, the tools
in tool kit 99 571 should be used. The kit
Introduction contains these tools:
The following instructions show how an • Holder 99 569
overhaul of the injectors in the Scania HPI-fuel
system should be carried out. • Wrench 99 570, 2 off
For more information, refer to section 03-01
Injection pump and injectors in the Workshop
Manual.

IMPORTANT! Local environmental

legislation and rules on handling diesel and the
working environment- and health regulations
for each market regarding work on fuel
systems should be adhered to.

IMPORTANT! Cleanliness is extremely

important when working with fuel systems. An
example of this is that one single piece of hair
or lint from a sweater is considered a major
contaminant while work is being carried out on
unit injectors. A clean, dust-free environment
is therefore absolutely essential.

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Checks

Unit injector with coil spring

casing
1 Pushrod
2
• a) Screw
• b) Upper part of coil spring casing
• c) Separator insert
• d) Lower part of coil spring casing
3 Lock pin
4 Upper piston
5 Upper return spring
6 Seal
7 O-ring
8 Intermediate piston
9 Preload spring
10 Cylinder housing
11 Filter ring
12 O-ring
13 Sleeve
14 Lower piston
15 Lower return spring
16 O-ring
17 Spring housing
18 Filter ring
19 O-ring
20 Screw
21 Check valve
22 Sealing washer
23 Injection nozzle
24 Threaded socket nut
25 Copper gasket

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 Checks

Unit injector with retaining ring

spring casing
1 Pushrod
2 Retaining ring spring casing
3 Retaining ring
4 Upper piston
5 Upper return spring
6 Seal
7 O-ring
8 Intermediate piston
9 Preload spring
10 Cylinder housing
11 Filter ring
12 O-ring
13 Sleeve
14 Lower piston
15 Lower return spring
16 O-ring
17 Spring housing
18 Filter ring
19 O-ring
20 Screw
21 Check valve
22 Sealing washer
23 Injection nozzle
24 Threaded socket nut
25 Copper gasket

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Checks

External cleaning and leak

test of unit injector
1 Clean the unit injector assembly using cold
degreasing agent. Dry it with compressed
air.
2 Carry out a leak test of the injectors to
verify that the check valves are operating
correctly, refer to Checking the unit
injector check valve.

Dismantling and cleaning

the component parts of
the unit injector

Dismantling unit injectors

The following description contains Upper filter ring Lower filter ring
references to positions taken from the
exploded views on pages 30 and 31. A 37.2 36.3

To facilitate the removal of the filter rings, B 33.8 31.8

2 tools can be made, one for each size of filter C 5.5 5.5
ring. The tool should be 7 mm thick. Other
dimensions are given in the table. D 33.0 33.0
E 43.0 43.0

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 Checks

IMPORTANT! To avoid malfunctions no

injector must under any circumstances be
assembled with parts from other injectors. The
pistons are adapted in size in relation to the
bore of the respective cylinder. The height of
the injector is adapted to the height of the
3 pistons.

1 Remove the pushrod 1.

2 Remove the copper gasket 25, O-rings 7,
12, 16, 19 and the filter rings 11, 18. Place
the tool against the filter ring as illustrated
and gently tap the tool shaft with a mallet.

Make a tool in order to open the filter ring

snap lock.

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Checks

3 Place the injector in tool 99 569. Secure

the tool with the injector in a vice.

4 Remove the spring casing 2.

• Injectors with retaining ring spring
casing: Push down the spring casing 2
so that the upper return spring 5
becomes slightly compressed. Remove
the retaining ring 3 with, for example, a
screwdriver. Remove the spring casing,
the upper piston 4 and the upper return
spring.
• Injectors with coil spring casing:
Remove the screw 2a. Remove the
upper section 2b of the spring casing.
Remove the separator inserts 2c, the
upper piston 4 and the upper return
spring 5. Tap out the lock pin 3 holding
the lower section of the spring 1 With retaining ring spring casing
casing 2d and remove the spring 2 With coil spring casing
casing.

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5 Remove the seal 6 using a drift or similar.

IMPORTANT! Make sure the cylinder

housing bore is not damaged.

IMPORTANT! Do not mix up the component

parts of different injectors.

6 Detach the cylinder housing 10 using tools

99 570. Hold onto the spring housing 17.
7 Remove the cylinder housing and the
intermediate piston 8. Be aware that the
intermediate piston is loose in the cylinder
housing.
8 Remove the sleeve 13.
9 Remove the preload spring 9, the lower
piston 14 and the lower return spring 15.
10 Unscrew the spring housing from the
injection nozzle 23 with tool 99 570.
11 Dismantle all injectors in the same way.
If the leak test indicated that the check valve is
leaking, the check valve and the sealing washer
inside it must be renewed, refer to Renewing
the unit injector check valve.

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Checks

Cleaning the component parts of

the unit injector
• Wash the component parts in ultrasonic
washer 588 099 at a temperature of
80-90°C for 30 minutes. The detergent
588 157 must be clean.
• Dry the washed parts with compressed air.
• Blow the outlet plugs clean with
compressed air.

• Blow the TVS-hole clean (Trapped

Volume Spill) with compressed air.

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Renewing the unit injector

check valve
IMPORTANT! Remove the check valve only
if it is leaking.

When renewing the check valve the sealing

washer also has to be renewed. Make sure that
only one sealing washer is in place before the
new check valve is fitted.
1 Remove the screw 20 for the check
valve 21 from the injection nozzle 23. Use
a Torx-wrench T20.

2 Flip the injection nozzle round to make the

check valve fall out. Make sure that the
sealing washer 22 is taken out from the
injection nozzle by tapping the turned
injection nozzle over a piece of clean
paper.

3 Fit a new sealing washer.

4 Fit a new check valve. The valve is to be
fitted so that the pin points upwards, from
the sealing washer.
5 Fit the screw, tightening torque 6 Nm.

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Checks

Checking the injection

nozzle wear and spray
pattern

IMPORTANT! Use calibration fluid when

inspecting the injectors. The calibration fluid
must conform to ISO 4113 and be absolutely
clean.

Checking for wear

Use a microscope or magnifying glass to check
that the tip of the injection nozzle is not
damaged or worn. If the yellow or black
surface treatment on any of the pistons is worn
through, the complete injector has to be
discarded. Otherwise the injector can be
reused.
Check that the tip of the lower piston is intact.
Inspect the tip with a microscope or a
magnifying glass. If necessary, renew the
injector.

Note: There may be unit injectors whose

pistons have differently-coloured surfaces in
the same engine.

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Checking the spray pattern

! WARNING!

Use eye protection.

Make sure that the place where the check is

carried out is well ventilated.
A simple check can be carried out to make sure
that the fuel can pass through the holes in the
injection nozzle and give a correct spray
pattern:
1 Fill the nozzle with calibration fluid.
2 Carefully place the lower piston in the
nozzle.
3 Push in the piston so that the fluid is
pressed out of the hole in the nozzle.

Another method is to use a spray can with

cleaning spray, see the illustration. This
method gives a longer-lasting spray pattern
which is easier to check.

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Checks

If the spray pattern is incorrect (the fluid does

not come out of all holes), the injection nozzle
should be cleaned once more in the ultrasonic
washer.
If the spray pattern after the second cleaning is
still incorrect, the injector should be discarded.
If the spray pattern is correct, the fluid will be
distributed evenly among the holes.

IMPORTANT! The holes in the injection

nozzle are very small and must not be cleaned
with a cleaning tool. Damaged holes in the
injection nozzle cause smoke emissions, high
fuel consumption and reduced power.

Principle drawing of an incorrect spray

Note: The spray patterns of new and old pattern.
injectors will differ. This is because the
injection nozzle becomes worn over time.

Principle drawing of a correct spray pattern.

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Assembling unit injectors

IMPORTANT! No injector must under any

circumstances be assembled with parts from
other injectors. This will lead to major
malfunctions as all pistons are matched to the
bore of each cylinder. The height of the
injector is adapted to the height of the
3 pistons.

Note: Dip all component parts in clean

calibration fluid in conjunction with the
assembly.

1 Screw together the spring housing 17 with

the injector 23. Tighten the threaded
socket nut 24 by hand.
2 Place the assembled parts in tool 99 569.
Secure the tool in a vice.

3 Place the lower return spring 15 on the

lower piston 14 and place them in the
spring housing. Push down the piston by
hand and check that the spring mechanism
is functioning without seizing up.

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Checks

4 Fit the sleeve 13 on the cylinder

housing 10.
5 Screw together the cylinder housing with
the spring housing by hand.
6 Drop the preload spring 9 and the
intermediate piston 8, with the pin
downwards into the cylinder housing.
7 Tighten the cylinder housing against the
spring housing, 40 Nm. Use tools 99 590.
8 Tighten the spring housing against the
injection nozzle, tightening torque 40 Nm.

9 Fit a new seal 6 in the cylinder housing.

Make a new assembly drift from the banjo
screw 812 393. Machine the inside and the
outside of the banjo screw so that the inner
diameter becomes 17 mm and the outer
diameter 20 mm.
10 Injectors with coil spring casing: Fit the
lower section of the spring casing 2d and
the lock pin 3.

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11 Fit the upper return spring 5 and the upper

piston 4 in the cylinder housing.
12 Fit the spring casing.
• Injectors with coil spring casing: Fit
the separator inserts 2c and the upper
part of the spring casing 2b. Fit the
screw 2a, tightening torque 57 Nm.
• Injectors with retaining ring spring
casing: Fit the spring casing 2, push
together the upper return spring and fit
the retaining ring 3.
13 Fit the pushrod 1 into the upper piston.
14 Carry out a leak test on the injectors and
make sure that the check valves are
operating correctly, refer to the section
Checking the unit injector check valve.
15 Fit new filter rings, O-rings and copper
washers on the injectors.

IMPORTANT! Lubricate the unit injector at

the bottom of the pushrod and at the upper
piston with engine oil when replacing it or
fitting a new injector. This makes sure the
injector is lubricated right from the start.

16 Refit the unit injectors in the vehicle, refer

to section 03-01 Injection pump and
injectors in the Workshop Manual.

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