Contents: Removal ↡ Installation ↡
Removal
Attention! The procedure for removing fuel injectors is the same. Therefore, removal and installation are shown using one injector as an example.
1. Remove the intake manifold, see the relevant chapter.
2. Remove the catalyst, see the relevant chapter.
3. Remove the turbocharger, see the relevant chapter.
4. Disconnect the tip from the injector (power plug).
5. Remove the oil filler pipe together with the crankcase ventilation hose.
6. Disconnect the fuel supply line from the injector.
When unscrewing the union nut of the fuel line, hold the injector from turning with a wrench by the hexagon.
Attention! Changing the bend shape of the fuel lines is not allowed. Plug the holes of the disconnected fuel lines with plugs to prevent dirt from getting into them. Inspect the sealing seat cone of the fuel lines. If the fuel lines show signs of flattening, replace them with new ones.
7. Unscrew the mounting bolts and remove the injector heat shield.
8. Release the fuel return line retaining clip and disconnect it from the injector.
Caution! The retaining clip must remain on the injector body. If it is removed, it must be replaced with a new one.
9. Unscrew the bolt of the injector mounting bracket. The bolt has a head for a multi-sided socket wrench.
10. Remove the nozzle together with the bracket from the fitting using a suitable screwdriver.
Attention! If the nozzle fits tightly, it should be removed using a puller and special pliers. To do this, remove the coil and install a threaded adapter (nipple). In this case, the nozzle should be replaced with a new one.
11. Clean the body of the nozzle and sprayer with a metal brush. The sprayer (nozzle) of the nozzle itself should be cleaned with a soft cloth.
Lubricate the injector mounting pin with a special grease, for example, MERCEDES-BENZ 001 989 42 51 10.
Before cleaning the nozzle seat, close the hole where the spray nozzle enters with a suitable bolt or plug to prevent dirt from getting into the combustion chamber. And only then clean the hole first with a soft cloth, and then with oval and cylindrical brushes.
Then blow out the seat hole with compressed air and close it. After that, wipe the hole with a soft cloth and remove the plug.
Attention! Disassembling the injector is not permitted.
Installation
12. Install the nozzle back into place together with the bracket, replacing it with a new sealing ring.
13. Screw in the injector retaining bracket mounting bolt. Do not tighten the bolt.
14. Loosen the main fuel distribution line mounting bolts. This is necessary to secure the supply fuel lines to the injectors without stress.
15. Secure the fuel supply line to the injector by screwing on the union nut. Do not tighten the union nut.
16. Tighten the main fuel distribution line mounting bolts to 9 Nm.
17. Tighten the bolt securing the bracket that holds the injector.
The tightening torque of the bolt is 7 Nm. After this, tighten the bolt by 180° (1/2 turn).
18. Tighten the union nuts securing the fuel supply lines to the injectors, while holding the injector with a hex wrench to prevent it from turning.
The tightening torque of the union nut of the new fuel line is 22 Nm.
Attention! Exceeding the nominal tightening value of the union nut is not permitted.
19. Connect the fuel return line and secure it with a wire clamp.
20. Install the injector heat shield in place.
21. Connect the injector power plug.
22. Install the turbocharger.
23. Install the catalyst.
24. Install the intake manifold.