Caution: Handling injectors requires extreme caution. Be careful not to let fuel from the injectors come into contact with your skin, as this can cause serious irritation. We strongly recommend that you entrust all work related to pressure testing of injectors to a specialist.
1. Remove the air cleaner with air ducts (see section 3).
2. Clean the surfaces around the injectors and the nuts on the fuel line fittings of the injectors.
3. Disconnect the return pipes from the injectors (see photo).
4. Loosen the nuts on the fuel line fittings on the high-pressure fuel pump side.
5. Unscrew the fitting nuts and disconnect the tubes from the injectors (see photo). If desired, the tubes can be completely removed.
6. Unscrew the injectors (using a 27 mm wrench) and remove them from the cylinder head.
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7. Remove copper washers, fire-resistant sealing washers and bushings from the cylinder head (see photos).
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8. Prepare new copper and fire-resistant washers.
9. Be careful not to drop the injectors or damage their needles. Injectors are precisely adjusted precision devices and must be handled with care (do not clamp in a vice under any circumstances).
10. Checking and calibration of injectors is performed by a specialist.
11. Start installing the injectors by installing the bushings, then the fireproof washers (convex surface upwards) and copper washers.
12. Insert the injectors and tighten them to the required torque (see photo).
13. Install the fuel injector pipes and tighten the fitting nuts to the required torque.
14. Connect the return pipes (see photo).
15. Install the air cleaner with air ducts.
Injector bushings - removal
1. If the injector bushing is tight in the cylinder head, you can try to remove it as follows. First of all, fill the bushing hole with grease to prevent dirt from getting into the combustion chamber.
2. Cut a thread in the bushing using a suitable tap and screw a stud with a suitable thread into it.
3. Using a thick washer that touches the cylinder head, screw the nut onto the stud and tighten it. Pull out the bushing.
4. When installing a new bushing into the cylinder head, you can use the old injector as a punch. Do not install the sealing washer or fire ring until the bushing is in place.