Warning: The diesel common rail system is under very high pressure. Damage or personal injury may result if the safety procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are not followed – see "Safety Regulations – Engine, Fuel and Exhaust System" . Do not disconnect fuel injector, loosen or remove fuel lines when the engine is running. As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect in the connections causing electrical problems.
Note. Engine is to be at normal operating temperature.
Remove
- 1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently (approximately 30 seconds). This waiting period is absolutely essential for fuel rail to be depressurised
- 2. Disconnect battery negative lead • Release nut
- 3. Disconnect 2x harness connector from engine control module (ECM)
- 4. Connect battery negative lead • Secure nut 11 Nm
- 5. Remove fuel injectors – see operation “One Fuel Injector Replacement”
Measure
- 6. Clean 4x injector seat with Cleaner EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)
- 7. Install Compression Test Adapter EN-46782 (1) to No. 1 cylinder • Secure Adapter EN-46782 to 20 Nm
- 8. Install Adapter EN-46783 (2) to EN-46782 • Secure Adapter EN-46782 to 20 Nm
- 9. Install compression tester (commercially available) (3) to Adapter EN-46783
Note. Use compression tester with a measuring range of 10-40 bar.
- 10. Connect battery negative lead • Secure nut 11 Nm
- 11. Crank engine and check compression of No. 1 cylinder
Note. 2x technician are required.
Note. Cranking speed at least 200 rpm using fully charged battery.
- 12. Release pressure from compression tester
- 13. Remove compression tester with Compression Test Adapter EN-46782 from No. 1 cylinder
- 14. Repeat the test procedure on cylinders No. 2, 3 and 4
- 15. Compare compression values • Maximum pressure difference 1.5 bar
- 16. Disconnect battery negative lead • Release nut
Install
- 17. Install fuel injectors – see operation “One Fuel Injector Replacement”
- 18. Connect 2x harness connector to ECM
- 19. Connect battery negative lead • Secure nut 11 Nm
- 20. Program all volatile memories – see operation “Program Volatile Memories”