Attention: work with nozzles requires extreme care. Make sure that the fuel supplied by the nozzles does not get on the skin, because. this can lead to serious irritation. We strongly recommend entrusting a specialist with all work related to checking pressure injectors.
1. Remove the air cleaner with air channels (see section 3).
2. Clean the surfaces around the injectors and nuts of the injector fuel tube fittings.
3. Disconnect the return pipes from the injectors (see photo).
4. Loosen the nuts of the fuel pipe fittings on the injection pump side.
5. Unscrew the union nuts and disconnect the tubes from the injectors (see photo). If desired, the tubes can be completely removed.
6. Unscrew the nozzles (with a 27 mm wrench) and remove them from the cylinder head.
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7. Remove copper washers, fire-resistant sealing washers and bushings from the cylinder head (see pictures).
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8. Prepare new copper and fire-resistant washers.
9. Be careful not to drop the nozzles or damage their needles. Nozzles are finely tuned precision devices and must be handled with care (never clamp in a vise).
10. Checking and calibration of injectors are carried out by a specialist.
11. Start installing the nozzles by installing bushings, then fireproof washers (convex surface up) and copper washers.
12. Insert the nozzles and tighten them to the desired torque (see photo).
13. Install the fuel pipes of the injectors and tighten the union nuts to the required torque.
14. Connect return pipes (see photo).
15. Install the air cleaner with air channels.
Nozzle bushings - removal
1. If the nozzle sleeve is tight in the cylinder head, you can try to remove it as follows. First of all, fill the bushing hole with grease so that dirt does not get into the combustion chamber.
2. Thread the bushing with a suitable tap and drive a stud with suitable threads into the bushing.
3. Using a thick washer touching the cylinder head, install a nut onto the stud and tighten. Pull out the bushing.
4. When installing a new sleeve in the cylinder head, you can use the old nozzle as a beard. Do not install the sealing washer or fire ring until the bushing is in place.