Nozzle — removal and installation (Freelander 1)

Dismantling

1. Disconnect "negative" battery terminal.

WARNING: Fuel vapors are highly flammable and in an enclosed area are also toxic and explosive. When working with fuel, it is necessary to have a foam type, carbon dioxide fire extinguisher at hand (CO₂), gas or powder.

2. Remove the high pressure tube.

DIESEL ENGINE FUEL SUPPLY, REPAIR WORK, High pressure pipe.

3. Close inlet channels of a head of cylinders.

CAUTION: Before disconnecting or removing system components, make sure that the surfaces adjacent to the connection points are free of dirt. Install plugs in fittings and piping to keep dirt out of the system.

4. Disconnect the fuel return hose from the clamp on the valve cover.

5. In order to remove only the nozzle of the 1st cylinder, remove the oil filler cap, unscrew the 5 screws and remove the air filter cover.

6. Disconnect the electrical connectors from the fuel injectors.

7. To remove injectors #2, 3, and 4: Remove 3 screws and move aside the injector harnesses.

8. Release the clamps and remove the fuel return hoses from the injectors. Dispose of seals.

9. Turn away 2 nuts of fastening of a nozzle.

10. Using a Torx socket, turn the injector mounting studs counterclockwise and remove the injector.

11. Remove the nozzle with the presser foot and discard the sealing washer.

Installation

1. Clean the injector and its seat in the cylinder head.

2. Tighten the injector mounting studs. Tightening torque 10 Nm.

3. Install the nozzle with a new sealing washer and presser foot.

4. Tighten the nozzle presser foot nuts evenly. Tightening torque 10 Nm.

5. Keep the fuel return hose connections clean.

6. Install new seals on the backflow hoses, wring out the clamps and install the hoses on the nozzles.

7. If injectors #2, 3, or 4 were removed, reinstall the injector wire harness and secure with screws.

8. If the nozzle of the 1st cylinder was removed, put in place and secure the air filter cover, install the oil filler cap.

9. Attach the fuel return hose to the clamp on the valve cover.

10. Connect the connectors to the injectors.

11. Install the high pressure pipes.