Table of contents: Removal 🠇 Installation 🠇
Removal
Note: After turning off the ignition, wait 15 minutes before disconnecting the battery to ensure that the initialization results of several different ECUs are remembered.
Special tools for removing injectors:
1 - torque wrench 1603-A;
2 - tubular tip 1603-G;
3 - extension cord 1603-E;
4 - tubular tip 1603-1;
5 - torque wrench 1608-A;
6 - Angle tightening key 1608-C;
7 - head for bolts with a hole for a hexagon 1608-D;
8 - T-shaped extension 1608-E;
9 - set of plugs 0188-T.
Disconnect the battery.
Note: Clean the high pressure tubes before unscrewing them.
Turn away:
- connections (1), holding the nipple on the nozzle (A) with an open-end wrench;
- connections (2).
Note: Plug the holes with plugs 9 as you remove the high pressure fuel pipes.
Remove the fuel return pipe (3) on the injectors.
Remove nuts (4), centering bushings (5) and leather washers (6).
Caution: Do not turn the nut (B).
Installation
Reinstall the guide bolts (7) (if they were removed) into the cylinder head.
Remove plugs 9 closing the injector wells.
Make sure that the bracket (8) is still secured to its retaining ring.
Install:
- new leather pads (6);
- new centering bushings (5);
- injectors.
Check for the presence of anti-vibration bushings (9) on the fuel supply pipes to the injectors on the camshaft support cap housing. Remove plugs 9 as you install the pipes.
Install new high-pressure fuel lines in place. Tighten the threads by hand until they stop.
Install the connecting elements (1) leading to the injectors.
Install the connecting elements for the pipes on the high pressure fuel rail (2).
Caution: Make sure that the high-pressure fuel pipes are correctly positioned on the anti-vibration bushings (9).
Replace the nuts (4).
Note: Tighten the nuts (4) securing the diesel injectors by hand (while hand tightening, ensure that the bracket (8) is positioned horizontally and is fixed on its retaining ring).
Caution: Stop tightening by hand when the snap ring contacts the camshaft bearing cap housing.
Tighten the nuts (4) to 4 Nm (using devices 5-7). Perform an angular tightening of 45° ±5° of the nuts (4) (using the 6-7-8 devices).
Caution: Tighten gradually and in one pass.
Pre-tighten using tools 1-2-3-4:
- tube fasteners (2) with a torque of 225 Nm;
- fastening elements of tubes (1) with a torque of 225 Nm.
Reinstall the diesel fuel return pipe (3) on the injectors.