101402-9270 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1014029270

Start By:
Do not let the tops of the nozzles turn while the fuel lines are loosened. The nozzles will be damaged if the top of the nozzle turns in the body. Defective fuel nozzles will damage the engine due to improper spray patterns.
a. remove fuel injection lines
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove clamp (1). 2. Install tool (A). Move the screw out of the poller enough to engage the inside lip of the puller on the lower stepped diameter of the nozzle.
Do not exceed a torque of 17 N m (13 lb ft) on the screw in tooling (A) to remove the nozzle. Added force can cause the stem of the nozzle to vend or break off.
3. With the nozzle bleed screw seen through the clearance hole in tooling (A), turn the screw down until the tip of the button goes down into the thread in the hole for the nozzle clamp bolt. When tooling (B) is used, the nozzle must be replaced.4. If the nozzle can not be removed with tooling (A), tooling (B) must be used.
Hold tool (B) so the center line of tool (B) is the same as the extended center line of fuel injection nozzle (2). This will prevent distortion of the fuel injection nozzle which can cause the nozzle to bend or break off.
5. Remove the protective cap and install tooling (B).6. Use the slide hammer to remove fuel injection nozzle (2).7. For nozzles removed using tool (A), remove the carbon dam seal on the end of the nozzle. The following steps are for the installation of the fuel injection nozzles. Tool (C) must be modified by drilling it out to a diameter of 8.5 mm (.344 in) and to a depth of 1.5 mm (.060 in) before it can be used on the 8N7002 Fuel Nozzles. 8. Use tool (C) to install carbon dam seal (4).9. To clean the nozzles, see Special Instruction SEHS7292 for the use of tooling (D).10. Install new seal (5). 11. Use tool (D) to clean the bore for the fuel injection nozzle. Use as open end wrench of tap driver to turn tool (E).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzle turns in the body.
12. Install fuel injection nozzle (3). Put the nozzle in position with the bleed screw away from the rocker arm cover and install clamp (1).End By:a. install fuel injection lines
Perform Scheduled Oil Sampling after performing service work to check for fuel leakage and contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.