434 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul
5.6.8 Injector – Overview
Injector – Overview
1 Hold-down clamp 3 O-ring 5 O-ring
2 Hex screw 4 Injector 6 CE-ring
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Task Descriptions 435
5.6.9 Injector – Removal
Special tools
Designation / Use Part No. Qty.
Puller F30377769 1
Puller bracket F6557991 1
Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Remove injector
1. Remove H.P. line (2).
2. Remove screw (1) from hold-down clamp (2).
3. Take off hold-down clamp.
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436 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul
4. Place puller (4) on injector (1).
5. Turn locking sleeve (2) of puller (1) from position
"a" to position "b".
6. Secure locking sleeve with nut.
7. Place puller bracket (2) on cylinder head.
8. Screw in threaded rod (3) in puller (5).
9. Secure nuts (4).
10. Withdraw fuel injector by turning nut (1) to the right.
11. Remove special tool.
12. Remove puller bracket and locking sleeve.
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Task Descriptions 437
13. Remove fuel injector.
14. Remove O-rings (2) from injector.
15. Remove sealing ring (1) from injector or use wire
hook to remove from cylinder head.
16. Seal all connections and installation bores with
covers or plugs.
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438 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul
5.6.10 Fuel injector disassembly
Disassembly of this component is not planned.
This component is an exchange component (Reman) and is available through the usual exchange procedure.
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Task Descriptions 439
5.6.11 Injector – Cleaning
Material
Designation / Use Part No. Qty.
Cleaner (Snow-White 11-0) 40460 1
Cleaner (Hakupur 312) 30390 1
Compressed air.
Risk of injury!
WARNING • Do not direct compressed-air jet at persons.
• Wear protective goggles / safety mask and ear protectors.
Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Cleaner is extremely caustic.
Risk of injury and suffocation!
WARNING • Avoid contact with eyes and skin.
• Do not inhale vapors and smoke.
• Do not eat, drink, smoke when working with cleaner.
• Wear protective clothing, gloves, and goggles / safety mask.
• Take measures against electrostatic charging.
Excessive reaction time of cleaning agents on components.
Damage to component!
CAUTION • Observe manufacturer’s instructions.
• Wear protective clothing, gloves, and goggles / safety mask.
Injector – Cleaning
1. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
2. Dry all components using compressed air.
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440 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul
5.6.12 Injector – Check
Material
Designation / Use Part No. Qty.
Crack testing oil (NR. 63) 40475 1
Crack testing paste (UV-Apelux Paste 1031) 40483 1
Spare parts
Designation / Use Part No. Qty.
Fuel injector
Hold-down clamp
Screw
Check injector
Item Findings Action
Inspect fuel injector externally for Damaged Replace
damage.
Check screws and hold-down Indication of cracks Replace
clamp for cracks with magnetic
crack-testing method.
Check contact surfaces of hold-down Damaged • Rework: smooth with oilstone.
clamp. • Replace
Inspect sealing cone of fuel injector Damaged Replace injector.
for damage.
Check cable connections for Damaged Replace wiring harness.
damage.
Check thread on screw and injector Sluggish • Rework
valve for ease of movement. • Replace
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Task Descriptions 441
5.6.13 Injector – Installation
Special tools
Designation / Use Part No. Qty.
Insertion tool F30378403 1
Lever F6555197 1
Force-in lever F6557952 1
Material
Designation / Use Part No. Qty.
Petroleum jelly, white 40317 1
Engine oil
Grease (Retinax EP2) 40388 1
Spare parts
Designation / Use Part No. Qty.
O-rings
Sealing ring
Fuels are combustible.
Risk of fire and explosion!
WARNING • Avoid open flames, electrical sparks and ignition sources.
• Do not smoke.
Check injector (→ Page 440).
Injector – Installation
1. Coat O-rings with petroleum jelly.
2. Fit O-rings on fuel injector.
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442 Diesel Engine 12V 4000 R41 / 16V 4000 R41 (1) – Instructions for Major Overhaul
3. Use Retinax EP2 grease to fit sealing ring on
mating face of injector.
4. Fit sealing ring on injector so that the even contact
surface faces injector.
5. Insert fuel injector (1) in cylinder head. Ensure
that injector is correctly aligned with H.P. fuel
line connection.
6. Fit force-in tool (2).
7. Lock force-in lever (1) of forces-in tool between
the pushrods.
8. Release palm grip (3) and move pressure element
(2) to correct position for force-in tool.
9. Secure palm grip and press injector (4) with
force-in lever into cylinder head.
10. Remove force-in tool.
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Task Descriptions 443
11. Fit hold-down clamp (2) in correct position by hand.
Note: Tighten screw of hold-down clamp only
after connecting the H.P. line.
12. Hand-tighten screw (1) so that the injector is
still rotatable.
13. Install H.P. lines between connecting piece and
injector (→ Page 459).
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