Workshop Manual S3.8 Engine A030K288 (Issue 2) 01-2010 INSTALLATION 1. Apply a light coat of grease/oil to new sealing ring and place it in cylinder head. Fig. 18. 2. Screw in protective sleeve into cylinder head with adapter, 000 589 0309 and tighten to specified torque. Fig. 19. 3. Insert new copper washer for the injectors into protective sleeves. 4. Insert injectors into cylinder head after aligning the locating lug of the nozzle holder into slot provided into cylinder head. 5. Screw-in pressure screw for nozzle holder with socket, 000 589 0209 and tighten to specified torque. Fig. 20. Fig. 18 6. Install leak off line with new sealing washers and tighten banjo bolts to specified torque.
7. Connect high pressure line to injectors and delivery valve holder ensuring the pipes are free from tension. If necessary align pipes free of tension with special tool, 312 580 0085. Tighten high pressure lines cap nuts to specified torque. Fig. 21. 8. Screw-in and tighten inner screw plugs into cylinder head. 9. Tighten outer screw plug into the inner screw plug over sealing rings. 10. Fit high pressure line clamps. 11. Install cylinder head covers with gasket. Fig. 19 INSPECTION OF INJECTION NOZZLES (Injectors removed) 1. CHECKING NOZZLE OPENING PRESSURE Carefully remove carbon deposits from nozzle. Connect injector assembly to nozzle tester.
Depress nozzle tester lever down slowly with pressure gauge connected one stroke per second and read opening pressure when nozzle starts opening. If the opening pressure is too high or too low, disassemble and clean injection nozzle and adjust as required by selecting the adjusting shims. (If the pressure is too high, use thinner shims, if too low, use Fig. 20 34