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Fuel injector fault
A fuel injector fault can cause an engine misfire.
In order to find which injector is defective, operate the
engine at a fast idle speed. Loosen and tighten the
union nut of the high-pressure fuel pipe at each
injector. When the union nut of the defective injector
is loosened, it has little or no effect on the engine
speed.
Warning! Ensure that the fuel does not spray onto
your skin.
How to remove the fuel injectors
1 Disconnect and remove the high-pressure pipes
and the spill pipes. For early engines, remove the
relevant rocker box cover. Release the connection for
the leak-off fuel from the fuel injector and remove it
through the wall of the rocker box. For later engines,
remove the relevant pedestal rocker cover.
2 Release the relevant clamp and withdraw the fuel
injector. To remove a tight fuel injector, use the Slide
Hammer, 21825 849 (A1) and the relevant Adaptor
(A2): 21825 854 for M18 threads or 21825 860 for
M14 threads.
Caution: Ensure that the copper fuel injector sleeve
is not loosened in the cylinder head during the use of
the slide hammer.
How to correct the fuel injector sleeves
To improve the condition of the injector sleeves, use
the Reamer/facer tool for the injector sleeve. Grease
must be applied to both of the cutters before use, to
retain carbon and metal particles. Do not remove
more metal than is absolutely necessary to correct the
seat face. The maximum permissible depth of the
seat face, measured from the top face of the cylinder
head, is 104,25 mm (4.104 in).
Note: The Reamer/facer tool is assembled from
these tools: 21825 765, 21825 767 and 21825 768.
How to fit the fuel injectors
1 Check that the new injector is fitted with a new 'O'
ring seal in the machined groove near to the top of the
stem and check that the sleeve for each fuel injector
is clean.
2 If relevant, remove the connection for the leak-off
fuel from each fuel injector and fit carefully each fuel
injector into its sleeve, with the threaded hole for the
leak-off fuel toward the outer wall of the rocker box.
DO NOT use a sealing washer between the injector
and the seating face of the injector sleeve.
This document has been printed from SPI². Not for Resale
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3 Fit the assembly of the metal cup and rubber seal
against the head of each connection for leak-off fuel
and fit a new copper washer onto the thread. For
early engines, insert each connection through the
openings in the outer walls of the rocker boxes and fit
the connection into its fuel injector, finger-tight.
4 Fit the clamps to the relevant fuel injectors,
complete with a spherical washer for each clamp. Fit
the cap screws through the washers and the clamps
and tighten them to 60 Nm (44 lbf ft). For early
engines, when all the cap screws of the clamps are
tight, tighten the connections for leak-off fuel to 27 Nm
(20 lbf ft).
5 Check that the joint face of each rocker box is
clean. Fit a new joint for each rocker box cover and
align correctly the bolt holes.
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Continued
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