19
7. Engine Servicing
3. Remove the filter through the tank
filler.
4. Insert new filter with sealing gasket into
tank.
5. Fit fuel tap assembly and tighten retain-
ing screws.
6. Turn the fuel tap ON.
7. Refill the fuel tank. Bleeding of the fuel
injection system takes place automati-
cally.
7.12 Removing the injector
1. Slacken and remove the pump to injec-
tor fuel pipe (A) and hold the fuel pump
delivery valve holder with a spanner to
prevent it turning.
2. Disconnect the leak-off pipe (B) from
the injector.
3. Remove the two injector holding down
nuts (C).
4. Lift off the injector clamp (D).
5. Lift out the injector and the sealing
washer.
7.12.1 Injector Setting
The injector must only be set on a test rig to
203 bar (200atmos; 2950lbf in²).
7.12.2 Replacing the injector
1. Ensure the seatings in the cylinder head
are clean and smooth.
2. Fit the heat insulating washer onto the
Injector.
3. Replace the Injector into the cylinder
head, ensure dowel pin locates into the
slot.
4. Fit injector clamp over the two studs.
5. Replace the two clamp nuts leaving them
finger tight.
6. Replace the fuel pump to injector pipe
and tighten the unions finger tight.
7. Tighten the unions a further half turn
with a spanner.
8. Torque load the injector nuts to 10-
12Nm (7.5-9lbf ft).
9. Replace the leak-off pipe.
10. After the initial run following an injector
replacement, re-torque the two clamp
nuts.
7.13 Checking the Battery
1. Wear protective gloves and goggles.
2. Clean the top of the battery filler plug
area.
3. Remove the filler plugs and check that
the electrolyte level is 6.0-9.0mm (0.25-
0.37in) above the tops of the separa-
tors.
4. If necessary top up with distilled water.
In cold weather distilled water should
only be added immediately before run-
ning the engine.
5. Replace and tighten the filler plugs.
6. Check that the terminal connections are
tight; petroleum jelly will help to protect
them from corrosion.
WARNING
BATTERIES CONTAIN SULPHURIC ACID
WHICH CAN CAUSE SEVERE BURNS AND
PRODUCE EXPLOSIVE GASES.
IF THE ACID HAS BEEN SPLASHED ON THE
SKIN, EYES OR CLOTHES FLUSH WITH CO-
PIOUS AMOUNTS OF FRESH WATER AND
SEEK IMMEDIATE MEDICAL AID.
A
C
B
D
