Important

• Before proceeding with operation, read Par. 3.3.2.
• In the event of the electronic injectors being disassembled (not necessarily replaced) their position with respect to individual cylinders must not be changed when re-assembled. Refer to the reference between each injector and respective cylinder number.
• Seal all injection component unions as illustrated in Par. 2.9.8 during disassembly.
• Handle the components as described in Par. 2.17.
• Replace all seal gaskets after each assembly for all components on which they are provided.
• The high pressure pipes must be replaced every time they are disassembled.
• Before disassembling the electronic injectors, make sure the new high pressure pipes are available.
• If a new (or different) electronic injector is fitted on the engine, the new calibration data must be entered in the ECU through a specific instrument (ST_01).
• Electronic injectors are not repairable.
• This procedure may be performed on one or more electronic injectors.
  
  NOTE:  In the event of a leak upon replacement (oil - coolant - fuel - air), do not intervene with the engine running, but stop it and wait for 5/10 minutes before checking and solving the problem.

1. Disconnect the connector C.

2. Remove clips E from the electronic injector F.
3. Disconnect the junction G from the electronic injector F.
   
   

  Warning

• After removing the fittings, the clips E must automatically return to their initial position; otherwise they must be replaced.

3. Seal all injection component unions as illustrated inPar. 2.9.8.

6.1.2 High pressure fuel pipes disassembly (Common Rail/electronic injectors)

  Danger

• The fuel injection circuit is under high pressure, use safety protections as described in Par 3.4.3.
• Ensure that the Common Rail is not under pressure by slowly and carefully unscrewing one of the nuts H.
  
  

1. Undo the nut H on the Common Rail L and then the nut M on the electronic injector F and remove the pipe N.
   
   

  Important

• In the event that the electronic injectors are disassembled (not necessarily replaced), mark them with the relevant cylinder number from which they originate so as not to confuse them during re-assembly.
• Seal all injection component unions as illustrated in Par. 2.9.8.

6.1.3 Electronic injectors disassembly

1. Undo and remove the screw P with the washer R e and then the bracket Q.

  Important

• Be careful not to damage the gaskets X.
• Replace rings X, if damaged.

2. Pull out the electronic injector F.

NOTE: Should you be unable to remove the electronic injector (acting only on point BC), use an open-ended spanner (Ø 34 mm), by applying small rotations to unblock the component.

3. Seal all injection component unions as illustrated in Par. 2.9.8.
4. Ensure that gasket S has remained in the correct position (Fig. 6.6). Otherwise, recover the gasket from inside the electronic injector T manifold.

NOTE: Click by side to play the procedure.

  Important

• Always replace and lubricate the gaskets AA and S of the electronic injectors F with fuel, every time they are replaced.
• Reposition the electronic injectors (not replaced) by following the references made for disassembly, as indicated in Par. 6.1.2.
• If the engine is painted or protected with clear paint, clean the paint off the diesel injector F near to the part in contact with the gasket AB.
  

1. Insert the gasket S on the electronic injectors F (Fig. 6.7).
2. Insert electronic injector F into manifold T, being extra careful not to damage gasket AB and direct it as indicated in Fig. 6.7.

NOTE: to replace gaskets AB, follow the operations in Para. 7.12.1 and 9.5.9.

6.1.5 High pressure fuel pipes assembly

  Important

• Always replace the pipes N after each assembly.
• If the engine is painted or protected with clear paint, replace the fastening screws P to ensure the gaskets are sealed properly.

1. Position tube N in the Common Rail seat of the electronic injector; correct the position of the electronic injector by means of the entrance of the electronic injector unions F and Common Rail L.
2. Apply the nuts H and M by hand without tightening them.
3. Position the fastening brace of electronic injectors Q on capscrew surface AD, insert capscrews P in brace Q inserting washer R.

  Important

• Ensure that brace S is perfectly positioned onto the electronic injector.

4.  Tighten the fixing screws P of the electronic injector bracket (tightening torque at 20 Nm).
5.  Tighten the nut M (tightening torque at 25 Nm).
6.  Tighten the nut H (tightening torque at 30 Nm).

   Important

• Replace the pipes N (Fig. 6.8) if the screws P are stiff when tightened.

6.1.6 Fuel return pipes assembly

1. Check the condition of the gaskets AE.

2. Insert unions G onto electronic injectors F and block them with clips E.
3. Mount the connectors C on the electronic injectors F.
    

  Warning

• Slightly move the wiring support to check that there is no voltage in the electrical wire of connector C in correspondence with the outlet hole AF.
  
  
  

Fig 6.11