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.
Remove
- 1. Remove cover (1) from engine • Remove 4x bolt
- 2. 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
- 3. Remove injectors – see operation ”One Fuel Injector Replacement”
- 4. Remove oil filler cap
- 5. Remove cap from coolant compensation tank
- 6. Remove oil level dipstick from guide tube
Measure
- 7. Clean 4x injector seat with Cleaner EN-47632 • Loosen dirt with the brush side (1) • Remove dirt with the sponge side (2)
- 8. Remove blanking plug (1) from timing chain cover
- 9. Remove camshaft sensor • Disconnect harness connector • Remove bolt (1)
- 10. Rotate crankshaft clockwise until piston is at top dead centre (TDC), No. 1 cylinder on compression stroke • Raised edge on camshaft (1) must align with the front edge of the aperture for the camshaft sensor
Note. 2x technician are required.
- 11. Apply guidance marks • Apply mark on the timing chain cover and 4x mark on the bolt (1) of the camshaft drive gear
- 12. Install camshaft sensor • Use new seal • Secure bolt 7 Nm
Important. Crankshaft must not turn during checking procedure.
- 13. Engage first gear and apply parking brake
- 14. Install Adapter EN-46782 (1) to No. 1 cylinder • Secure Adapter EN-46782 to 20 Nm
- 15. Install Adapter EN-46783 (2) to EN-46782 • Secure Adapter EN-46782 to 20 Nm
- 16. Attach pressure loss tester (2) to EN-46782 (1)
- 17. Check pressure loss in cylinder No. 1 • The maximum permissible pressure loss difference between individual cylinders is approximately 10% • The maximum pressure loss of one cylinder should not exceed 25% • Investigate any acoustically perceivable escape of compressed air from – Intake system – Exhaust system – Coolant expansion tank – Oil dipstick guide tube – Oil filler cap
- 18. Measure corresponding pressure loss of each cylinder in firing order 1-3-4-2, turning engine in direction of rotation until next guidance mark
- 19. Disconnect and remove pressure loss tester
- 20. Put vehicle in neutral
Install
- 21. Install oil filler cap
- 22. Install pressure cap to coolant compensation tank
- 23. Install oil level dipstick to guide tube
- 24. Install injectors – see operation ”One Fuel Injector Replacement”
- 25. Install blanking plug (1) 11 Nm to timing chain cover
- 26. Install cover (1) to engine • Install 4x bolt 8 Nm