1000 series » How to renew an atomiser

Cautions:

• Atomisers must be removed and fitted by a person with the correct training.
• Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections.

1. Remove the fuel leak-off pipe.
2. Remove the union nuts (A1) of the high-pressure pipe from the atomiser and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps.
3. Remove the atomiser setscrews and remove the clamp (A2), the atomiser (A6) and its seat washer (A7). Remove the dust seal (A5) and the spacer (A4) and fit the spacer and a new dust seal onto the new atomiser.

Caution: Remove and discard the seat washer (A6). If the original seat washer remains in the recess for the atomiser, the nozzle protrusion will be incorrect when a new seat washer is added.

4. Put the new atomiser in position with its spacer, new dust seal and a new seat washer, ensure that the fuel leak-off connection (A3) is not toward the engine. Position the clamp and engage the atomiser setscrews. Ensure that the atomiser is not tilted and tighten the setscrews for the clamp evenly and gradually to 12 Nm (9 lbf ft) 1,2 kgf m.

Caution: Do not tighten the union nuts of the highpressure pipes more than the recommended torque tension. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet. Do not tighten the atomiser union nut more, as this can cause a restriction at the end of the pipe. This can affect the fuel delivery.

5. Fit the high-pressure fuel pipe and tighten the union nuts to 27 Nm (20 lbf ft) 2,8 kgf m. If necessary, fit the pipe clamps.
6. Renew the sealing washers and fit the leak-off pipe. Tighten the banjo bolt to 9,5 Nm (7,0 lbf ft) 1,0 kgf m.
7. Operate the engine and check for leakage of fuel and air.