LB400 Servicing and Cleaning CONTENTS: Page 2 Page 3 Page 4 Page 4 Page 5 Page 6 EFI Fuel System Checks EFI Fuel System Cleaning with Pressure Regulator EFI Fuel System Cleaning without Pressure Regulator Carburettor Fuel system Cleaning Diesel Fuel System Cleaning Diesel Common Rail Fuel System Cleaning
Page 2 EFI FUEL SYSTEM CHECKS With any E.F.I. servicing, the engine must be in good mechanical order. If it is not, you will only cover up faults and get yourself into trouble. Before commencing the service check the following. a. Fuel tank is at least _ full b. If the vehicle has an automatic transmission, put into NEUTRAL c. Turn off Air Conditioning if fitted d. Do not exceed gauge pressure of 400 kpa Connect LB400 into the fuel system as shown below. Drawing 1. 1. Fuel Tank A. Inlet hose to LB400 from fuel filter 2. Fuel Pump B. Outlet hose from LB400 to injector rail 3. Fuel Filter C. LB400 Return line hose to fuel tank 4. Injectors D. Fuel return line from Pressure regulator to fuel tank 5. Pressure Regulator E. Pressure Regulator Vacuum hose 6. Injector Rail G. LB400 Diverter Valve 1. Connect inlet hose (A) from fuel filter (3) to LB400 2. Connect LB400 outlet hose (B) to injector rail line (6) 3. Connect return line hose (C) to fuel tank (1) filler inlet. 4. Make sure valve (G) is closed and LB400 pressure canister is tightened. 5. Start the engine and bring up to operating temperature. 6. Switch off engine and check the fuel system rest pressure. Pressure should not drop. If pressure drops check the following: a. Make sure there are no leaks where hoses (A) & (B) are connected into the fuel system. b. If pressure drops clamp inlet hose (A). If pressure now holds, the check valve in the fuel pump is leaking or a leaking connection somewhere between fuel tank and clamp on hose (A). Applying back pressure by crimping outlet hose (B) to a maximum of 400 Kpa for a few seconds and then letting go may reseat leaking pump check valve. Repeat this 2 to 3 times. If this doesn t stop the leak, repeat this after a chemical treatment. c. If the system pressure still drops with the clamp on hose (A) then the leak is towards the engine. d. Clamp the pressure regulator return hose (D). If pressure stops dropping the pressure regulator is leaking. Reseat the pressure regulator by starting the engine and then clamp the return line hose to obtain pressure reading of 350 Kpa for a few seconds and then release clamp on return line hose (D). Repeat this 2 to 3 times. Switch off the engine. Never exceed 350 Kpa when clamping return line. e. NOTE: ON SINGLE SUPPLY TO RAIL SYSTEMS STEP D IS NOT POSSIBLE AS THE PRESSURE REGULATOR IS IN THE TANK WITH THE FUEL PUMP.
f. Remove vacuum hose from Pressure regulator (5) and make sure no petrol is leaking from vacuum pipe. If fuel comes out of vacuum pipe the diaphragm in the pressure regulator has a Split diaphragm. Fit new pressure regulator. g. If there is still a pressure drop with clamps on hoses (A) & (D) injectors will be leaking. Cleaning the injectors with our chemical through the machine should solve this problem. 7. Switch on the engine and with the motor at idle carry out the following checks. a. Fuel pump output capacity. This is obtained by crimping the outlet hose (B) by hand to restrict the fuel flow. The pressure as shown on the gauge should increase 50% to 75% over the normal pressure at idle. If the increase does not occur, check voltage to fuel pump and electrical connections, pump relay. If electrical is okay, then the fuel pump should be replaced. 8. Check fuel system pressure. Page 3 EFI Fuel System Cleaning with Pressure Regulator on Fuel Rail 1. Remove Pressure canister and fill with 250 mls of Injector cleaner (Part No 413R, Green Bottle) and screw back onto LB400 head. 2. Close Diverter valve (G). 3. Work ignition switch so as fuel pump goes to prime mode and pump the injector cleaner from the LB400 canister back to the fuel tank via the return line (D). Avoid engine running as we do not want the chemical to flow through the injectors, just to wash the filter buckets. You will see the pink chemical in the CLEAR fuel filter in hose (B). 4. Once the filter has returned to the colour of petrol, start the engine and run for 3 to 5 minutes. 5. Open Diverter Valve (G) until fuel pressure is 180 kpa on the pressure gauge. At 180 kpa the Pressure regulator (5) should be closed. 6. With the engine still running clamp Return line (D) from pressure regulator and pressure should not increase. If pressure does increase remove clamp and open Diverter Valve (G) more to drop the pressure to a point where there is no increase in pressure when Return line (D) is clamped. 7. With the Diverter Valve (G) opened in this position and return line (D) clamped, stop the engine. 8. Remove LB400 pressure canister (Take care as there will be system pressure when head is released) and fill with 500 mls of Blue Machine Cleaner, Part No 418/5 and screw back onto LB400 head. 9. Start the engine and with valve (G) set as per step 5 and return line (D) clamped, the 418/5 chemical is in the cleaning process. At no point, touch the Diverter Valve (G) or remove the clamp off Return line Hose (D). 10. Run the vehicle until normal petrol colour returns in the clear filter in hose (B). 11. Remove Clamp off return line (D) and close Diverter Valve (G). 12. When cleaning is complete, always reseat the pressure regulator (see Step 6.D, Page 2) and reseat the fuel pump check valve. (see Step 6.B Page 2) 13. Open Diverter Valve fully and stop the engine. 14. Remove the LB400 from the system and connect up the original fuel system hoses and pressurise the fuel system and check that there are no leaks.
Page 4 EFI Fuel System Cleaning without Pressure Regulator on Fuel Rail 14. Remove Pressure canister and fill with 250 mls of Injector cleaner (Part No 413R, Green Bottle) and screw back onto LB400 head. 15. Close Diverter valve (G). 16. Start engine and let idle until petrol colour returns in clear fuel filter. 17. Remove LB400 pressure canister (Take care as there will be system pressure when head is released) and fill with 500 mls of Blue Machine Cleaner, Part No 418/5 and screw back onto LB400 head. Run the vehicle until normal petrol colour returns in the clear filter in hose (B). 18. Run the vehicle until normal petrol colour returns in the clear filter in hose (B). 19. Open Diverter Valve fully and stop the engine. 20. Remove the LB400 from the system and connect up the original fuel system hoses and pressurise the fuel system and check that there are no leaks. Carburettor Fuel System Cleaning With any Interject servicing, the engine must be in good mechanical order. If it is not, you will only cover up faults and get yourself into trouble. Before commencing the service check the following. a. Fuel tank is at least _ full b. If the vehicle has an automatic transmission, put into NEUTRAL c. Turn off Air Conditioning if fitted 1. Run the engine until normal operating temperature is reached. 2. Pour 250 mls of Injector Cleaner (Part No 413R, Green Bottle) into the fuel tank and run the engine for 3 to 5 minutes. 3. Hook up the LB400 as shown in drawing 2 above. 4. Close Diverter Valve (G) on the LB400. 5. Any return lines from the carburettor to the fuel tank must be blocked off to stop Blue Machine Cleaner returning to the fuel tank. 6. Remove LB400 pressure canister (Take care as there will be system pressure when head is released) and fill with 500 mls of Blue Machine Cleaner, Part No 418/5 and screw back onto LB400 head 7. Start the engine and run at idle until all the Blue Machine Cleaner disappears from the Clear filter in line (B) to the carburettor.
Page 5 8. Switch off the engine and remove the LB400. 9. Reconnect vehicle fuel hoses and check that there are no leaks. Diesel Fuel System Cleaning With any Interject servicing, the engine must be in good mechanical order. If it is not, you will only cover up faults and get yourself into trouble. Before commencing the service check the following: a. Fuel tank is at least _ full. b. If the vehicle has an automatic transmission, put into NEUTRAL. c. Turn off Air Conditioning if fitted. 1. Run the engine until normal operating temperature is reached. 2. Pour 250 mls of Injector Cleaner Additive, Part No 413R into the fuel tank and run the engine for 3 to 5 minutes. If more than one fuel tank on the vehicle, pour 250 mls of Injector Cleaner Additive, into each tank. 3. Hook up the LB400 as shown in Drawing 3. a. Clamp the inlet line to the filter (2) to stop fuel draining back to the tank. b. Connect LB400 Inlet Hose (A) from the fuel filter to LB400. c. Fill the LB400 pressure canister with 500 mls of Diesel Cleaner, Part No 421/5. d. Connect the LB400 outlet hose (B) to the inlet fuel line on the Injector Pump. e. Close Valve (G) on the LB400. f. Remove the Tank return line (D) from the injector pump. g. Fit the Return line Hose (C), onto the injector pump return line outlet. h. Remove the clamp off the inlet line to the filter and with the aid of the lift pump situated on the filter or injector pump, prime the fuel system until all air is removed from hose (C) and connect to the LB400 as shown in Drawing 3. Fully open valve (G) and start the engine to start cleaning. i. After One hour or when the fuel colour returns to the diesel fuel colour, as seen in the Clear Filter in hose (B) switch off the engine. j. If after running the engine for 1 hour, there is still Cleaner in hose (B), Close valve (G), and remove hose (C) from the LB400 to tank return line outlet on the injector pump. k. Fit the vehicles return line (D) back onto the injector pump and restart the engine. After approximately 5 minutes the fuel colour in the clear tube in hose (B) will return to the diesel colour. l. Switch off the engine, remove LB400 and reconnect the original fuel system hoses. m. Pump the lift pump 5 to 6 times and start the engine and make sure there are no leaks.
4. Fuel injectors on a diesel engine do not spray fuel directly onto the inlet valves. To further enhance your Interject service, clean the inlet valves while the above cleaning process is being completed with the engine at idle. 5. Remove the air cleaner or the hose between the air cleaner and the inlet manifold or Turbo charger if fitted. The Diesel Induction Cleaner cannot be sprayed through an air filter. 6. Spray the 100 mls of Diesel Induction Cleaner, Part No 410 in small amounts into the inlet manifold or Turbo Charger. This will clean the turbo intercooler and engine Inlet Valves. 7. Refit the Air Cleaner and any air inlet hoses for the spraying application. Common Rail Diesel Fuel System Cleaning The following does not apply to Common Rail Systems with Electronic Pressure Regulator With any Interject servicing, the engine must be in good mechanical order. If it is not, you will only cover up faults and get yourself into trouble. Before commencing the service check the following: a. Fuel tank is at least _ full. b. If the vehicle has an automatic transmission, put into NEUTRAL. c. Turn off Air Conditioning if fitted. d. Do not exceed gauge pressure of 400 kpa Page 6 1. Fuel Filter 2. High Pressure Diesel Pump 3. Common Rail 4. Injector 5. Non-return Valve a. Inlet Hose to Machine b. Outlet Hose to Pump c. Return Line Hose from Filter to machine d. Return line from Injectors to Filter 1. Run the engine until normal operating temperature is reached. 2. Pour 250 mls of Injector Additive, (Part No 413R, Green Bottle), into the fuel tank and run the engine for 3 to 5 minutes. If more than one fuel tank on the vehicle, pour 250 mls of Additive into each tank. 3. Hook up the LB400 as shown on Page 6. 4. Clamp the Fuel supply hose from the filter (1) to High Pressure Pump to stop fuel draining back, and remove hose from the Filter (1) and connect LB400 Inlet Hose (A) to the Fuel Filter. Please Note: Use the short hose supplied with the One Way Non-Return Valve, Part No IJ7319, fitted to Hose (A) as shown. 5. Fill the LB400 pressure canister with 500 mls of Diesel Cleaner, Part No 421/5.
Page 7 6. Close Diverter Valve (G). 7. Prime the system until product 421/5 comes out of Outlet Hose (B) to bleed the system of air and connect Outlet Hose (B) to Fuel Supply Hose and remove clamp. Vehicles will have auto prime or Primer Bulb or Lift pump at the filter for this. 8. Remove Tank Return line from the Filter (1) and connect LB400 return Hose (C). 9. Remove Return Line Hose (C) from the machine and hold Hose (C) into a container to catch fluid. 10. Prime system until cleaner starts to flow out of Hose (C). Clamp off end of hose (C). 11. Fit Return Line Hose (C) onto the machine and remove Clamp. 12. Open Diverter Valve (G) fully and start the engine. 13. To further enhance your Inter-Ject service, clean the inlet valves while the above cleaning process is being completed with the engine at idle. 14. Remove the air cleaner or the hose between the air cleaner and the inlet manifold or Turbo, if fitted. The Diesel Induction Cleaner cannot be sprayed through an air filter. 15. Spray 100 mls of Diesel Induction Cleaner, Part No 410, in small amounts into the inlet manifold or Turbo. If the engine stalls if the airflow meter is disconnected you can spray through the meter and clean that at the same time. This will clean turbo, intercooler and remove any deposits off of the back of the inlet valve. The exhaust valve will be cleaned from the combustion side. 16. Replace Air Cleaner and any air inlet hoses that were removed. 17. After the Clear filter in hose (B) returns to the diesel fuel colour, switch off the engine. 18. Remove all LB400 hoses and reconnect vehicles hoses back on the filter and bleed any air from the system. Start engine and check for fuel leaks. 19. It is important that you do not over rev the engine stationary but take the vehicle for a good test drive. When you first take off do not gun the engine as there will be a build up of fuel and possibly induction spray in the engine. Drive the first one hundred metres sedately then it will ok to drive as normal after this.