INJECTORS
Remove
and
refit
19.60.01
Service tools: 18G 284, 18G
284
P
Removing
I
INA
.
2 Disconnect
the
spill rail from
the
injectors.
3 Disconnect
the
high-pressure pipes
from
the
injectors.
4 Remove
the
nuts
and
washers securing
the
injectors.
5 Withdraw
the
injectors, using tools
18G
284
and
18G
284
P
if
necessary.
6 Remove
the
two
sealing washers from
each injector position.
Refitting
7 Fit
two
new sealing washers
to
each
injector position, fitting
the
smaller
washer
as
shown.
8 Reverse
the
procedure
in I
to
5,
tightening
the
injector securing
nuts
to
121bfft
(1.7
kgf
m,
16 Nm).
9 If
more
than
two
injectors have been
removed,
crank
the
engine with
the
starter
motor
and
bleed at least
two
of
the
high-pressure pipes.
20°
fiq
~
I
cu.
4~
5~
7
6~1
5NC480
INJECTORS
Overhaul
19.60.08
Service tools: 18G 109
A,
18G 109
B,
18G
1091::;,
18G 210, 18G
388,
18G
487
I Remove
the
injectors, see
19.60.0
I.
2 Mount
the
injector in
tool
18G
388.
3 Remove
the
cap
nut
and
sealing
washer.
4 Remove
the
spring cap
and
shim.
5 Remove
the
spring.
6 Lift
out
the
spindle.
7 Remove
the
nozzle
nut
and nozzle,
using
tool
18G 210.
8 Renew
the
spring if it shows any sign
of
weakness
or
distortion.
9 Renew
the
spindle if it
is
not
perfectly
straight.
10 Clean
the
nozzle and valve, using kit
18G
487.
II
Reverse-flush
the
nozzle, using tools
18G
109
A
and
18G 109
E.
12 Renew
the
nozzle assembly
if
the
pintle clearance allows
an
angle
of
more
than
20°
when
checked
as
shown.
13
If
necessary, restore
the
nozzle
and
valve seats
to
the
angles given in
DATA.
14 Check
the
needle lift against
the
figure
in DATA.
I 5 Reverse
the
procedure
in 2
to
7,
tightening the nozzle
nut
to
50
Ibf
ft
(6.9
kgf
m,
68
Nm).
16 Test
and
set
the
injectors
to
the
specification given in DATA, using
tools
18G
109 A
and
18G
109
B.
17 Fit
the
injectors, see
19.60.0
I.
DATA
Auxiliary hole
diameter
..•........
Needle lift
...•.•..•..........
'.
Nozzle seat angle
..............
.
Valve seat angie
...............
.
Testing
TEST
NOZZLE
SET
ADAPTOR
TO OPEN
AT
(18G
109
B)
0.2 mm
0.70
to
0.75
mm
59°
0'
60°
0'
STROKES
PER
REQUIREMENTS
SET
TO OPEN AT
MINUTE
Auxiliary 135 Atm
220
Atm
60
Spray free
of
distortions.
Slight core permissible.
Spray
Main
135
Atm
220
Atm
140 Spray free
of
distortions.
Slight
core
permissible.
Seat tightness 100
Atm
- -
Dry nozzle
after
10
seconds at
90
Atm pressure·
Back-leakage 160
to
-
-
Initial pressure 160 Atm.
170
Atm
Time for pressure drop
from 150
to
100 Atm
to
!
be between 6 and 140
seconds
Final setting 135
Atm*
- - -
* Add 5
Atm
when
setting
new injectors
or
after
fitting new springs.
»
III
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