New 1000 Serie » How to remove an atomiser and to fit 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 from the connection (A2).
2. Remove the union nuts 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. Fit a plastic cap (A1) to cover the fuel inlet connection. Caution: Remove and discard the seat washer (A4). 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.
3. Release the clamp nut (A3) and remove the atomiser and its seat washer from the recess in the cylinder head.

How to fit an atomiser

Special requirements

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. Thoroughly clean the threads of the clamp nut and the cylinder head.

Caution: Do not allow any thread sealant to get below the clamp nut threads.

2. Ensure that the wire clip (A1) is in position. Put a 6 mm (0.24 in) long, 1 mm (0.04 in) wide bead of POWERPART Universal jointing compound, part number 1861117, around the first two threads of the atomiser clamp nut.
3. Put the new seat washer (A3) into the seat recess in the cylinder head.
4. Put the atomiser in position, ensure that the location ball (A4) is fitted in the groove (A2) correctly. Carefully engage the threads of the clamp nut with the threads in the cylinder head.

Caution: Do not move the clamp nut after it has been tightened, the seal that is made when torque has been applied will be broken and leakage past the atomiser seat may occur.

5. Ensure that the clamp nut is not cross threaded and tighten the nut gradually and evenly to 40 Nm (29 lbf ft) 4,1 kgf m. As the nut is tightened the atomiser will rotate clockwise as the ball moves in the slot. Remove any excess thread sealant.

Caution: Do not tighten the union nuts of the high-pressure 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.

6. Remove the plastic cap and 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.
7. Renew the sealing washers and fit the leak-off pipe. Tighten the M6 banjo bolt to 3,0 Nm (26.5 lbf in) 30,6 kgf cm.
8. Operate the engine and check for leakage of fuel and air.