Attention! Protect the generator from contamination.
After disconnecting the pressure pipelines, it is necessary to plug the openings of the injectors and pipelines with special caps.
If one of the sealing elements of the drain pipe for one group of cylinders is damaged, replace the entire pipe assembly.
Injection device type «Commom-Rail» shown in fig. 6.119. Replacement of injectors of the injection system must be carried out in the following order. Prepare fixtures «13.5.020», «13.5.231», «13.5.232» And «13.5.250» and materials for collecting escaping fuel for its subsequent disposal. Protect the generator from contamination. Detachable pipelines and injectors must be sealed with caps. Read information from the fault memory of the system ECU «DDE» and turn off the ignition. Remove intake manifold.
Loosen cap nuts (1, fig. 6.120) fastening of pressure pipelines (2) using a device «13.5.020» on the injector (4) and just loosen the nut on the accumulator. Loosen the nuts (3) mounting the injector and remove the injectors (4) from the cylinder head.
If it is impossible to remove the injector, it is necessary to assemble the tools «13.5.250», «13.5.231» And «13.5.232» and install it on the connecting element of the injector. Extract (knock out) injector using impact weight fixture «13.5.250».
Check for O-ring (1, fig. 6.121) on the removed injector. If not, then remove the ring from the cylinder head.
The installation of the injectors should be carried out in the reverse order, if necessary. Clean the injector channels. Replace o-ring (1) on the injector (2) and the sealing ring of the injector housing. Pay attention to the correct position of the flange (3). nuts (M6) fasten the injectors to tighten to 9.0 Nm (0.9 kgf·m).
The installation of pressure pipelines must be carried out in the following order:
- tighten all union nuts of pressure pipelines by hand;
- tighten union nuts on injectors to 23 Nm (2.3 kgf·m):
- tighten the union nuts on the hydraulic accumulator and HPP to a torque of 23 Nm (2.3 kgf·m)
- test drive at high engine speed. Visually check the tightness of all connections of the injection system components.
Attention! Correction of new injectors is necessary in order to ensure their full performance. In case of replacement of more than two injectors, it is necessary to «Correction of the injector characteristics field» according to the DIS tester documentation.
When installing new type injectors «EU3» count the first six digits/letters accordingly (sector, fig. 6.122). Enter numbers and letters according to the installation location (cylinders) new injectors into the software and perform a correction of the characteristics field.
When installing new type injectors «EU4» you need to count the first seven digits and letters, respectively (sector, fig. 6123). Enter numbers and letters according to the installation location (cylinders) new injectors into the software and perform a correction of the characteristics field.
Upon completion of the work on replacing the injectors, it is necessary to read the information from the fault memory of the system ECU «DDE». If they are found, take corrective action and erase the information from the ECU fault memory. Check system function «DDE».