Flaring Tool. Fuel Filter. Fuel Line Disconnect Tool. Fuel Line Nylon Repair. Fuel Line Retainer. Fuel Line Steel Repair. Fuel Sending Unit Repair. Fuel System Repair Manual. Hose Clamp. Hose Clamp Pliers. Hose Clamp Vise. Hose I. Hose Removal Tool. Multi-Use Hose. Remove the fuel injector hold down. NOTE: If injectors are tight, remove with special tool Remove injectors and discard lower sealing washer. Clean injectors and recesses. Right Cylinder Head.
Disconnect the high pressure fuel lines at the fuel injector. NOTE: Any time a new injector is installed, or if an existing injector is installed in any location other than its original location, the injector quantity adjustment procedure also called injector classification, must be performed.
Care must be taken not to restrict the discharge orifices in the nozzle. Coat injector body with anti seize lubricant then install injectors with new sealing washers. Tap: M8 x 1. Drill holding adapter 6.
Star socket Pilot drill centering sleeves Tap: M10 x1. Puller outer housing 7. Allen key Pilot drills 3. Puller adapter mandrels 4. Force screw See 3 8. Dual-size step drill M8 Precautions: The cylinder head can be removed to help eliminate the possibility of debris getting inside the engine. However, many technicians have performed this job successfully on the vehicle without removing the head. If cylinder head is to be left on during glow plug removal: Turn the engine to close the valves for the cylinder being worked on isolating that chamber.
This will prevent debris from going further inside the engine. Remove the fuel injector and connect air from an air compressor which will help blow out and prevent debris from entering the cylinder.
After the repair, and before installing the glow plug, crank the engine over to help blow out any remaining debris from the cylinder. Keep tools clean and well lubricated: Use motor oil or grease especially on taps to help prevent binding and excessive wear. Wear eye protection, especially when debris may become airborne. Place the star socket 6 on top of the glow plug.
It may need to be tapped on gently with a hammer. NOTE: When top portion of glow plug breaks, it may also shear off the inner glow plug electrode. If the inner electrode does not break, it can be removed completely from the glow plug body. In this case, go straight to step 5. If the inner electrode does shear off, then continue to step 3. Position centering sleeve 10 onto the remaining part of the glow plug. It may need to be tapped on. Using 3. Drill down at least 15mm past uppermost part of the glow plug body.
Fit either M8 8 or M10 9 dual-size stepped drill depending on the size of the glow plug to the drill holding adapter 2. Secure stepped drill into adapter by tightening the set screw with the provided allen key 7 ensuring the set screw contacts the flat part on the shank of the stepped drill. Be sure to keep the drill straight so the threads in the cylinder head are not damaged. Drill down again at least 15mm to remove all of the threaded portion. Use the correct size and thread pitch tap which may or may not be included.
Provided are common sized M8 x 1. Place the correct tap in the ratchet T-Bar 1. Clean out and re-cut the threaded portion of cylinder head. Coat the tap in grease to lubricate and also contain the metal shavings produced.
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