Contents: Removal ↡ Installation ↡
Fuel distribution line with injectors
1 - Retaining spring; 2 - Screw, 7Nm + 90°; 3 - Tightening clamp; 4 - Nozzle; 5 - Sealing ring; 6 - Pressure sensor, 22Nm, engine 611 up to factory no. 86512: 20Nm; 7 - Fuel injection pump; 8 - Holder, fuel distribution line to cylinder head; 9 - Holder, fuel line to cylinder head; 10 - Fuel distribution line; 11 - Bolt; 12 - Pressure regulating valve, tightening torque: 1st step 3Nm, 2nd step 5Nm; A - When installing, lubricate the injector with a thin layer of special grease only in this range.
Removal
Note: This describes the removal of one injector, the procedure for other injectors is similar.
1. Remove the top engine covers, refer to Section Removal and installation the top engine cover.
2. Disconnect the injector connector.
3. Remove the injection pipe leading to the injector. Hold the injector with a wrench while unscrewing the union nut.
Caution! Do not deform the pipelines when removing them. After removing them, close the ends of the pipeline. Make sure that no dirt gets into the pipelines. Check the connecting cones of the injection pipelines. If there are any dents, replace the pipeline.
4. Press the locking clip at the drain pipe connection point and disconnect the pipe.
Attention! The retaining clip remains on the injector. If the clip is removed, it will need to be replaced with a new one.
5. Remove the Torx screw on the clamp.
6. Remove the nozzle from the threaded adapter together with the clamp using a suitable screwdriver.
Note: A firmly seated injector can be removed using an impact puller and a suitable grip. If the puller rests against the cylinder head, unscrew the cylinder head cover mounting bolts or remove using a threaded injector adapter.
Attention! When removing with a threaded adapter, the injector must be replaced as a set.
7. Clean the rod and nozzles of the injectors with a wire brush, while the working part of the injector should be cleaned only with a highly absorbent cloth. Before cleaning the mounting shaft, close the nozzle opening in the shaft with a pin. First clean the mounting shaft with a highly absorbent cloth, then with a round and cylindrical brush, then blow it out and close it. Then clean it again with a highly absorbent cloth and close it. After cleaning, remove the pin from the nozzle opening.
Note: Clean the nozzle shaft only by hand (you should not use a drill for this). The injector should not be disassembled.
Installation
1. Lubricate the injector rod in area "a" with a thin layer of special grease, for example, MERCEDES-BENZ 001 989 42 51 10.
Attention! The lubricant should not get on the working part of the nozzle or on the sealing ring.
2. Install the injector in place with a new O-ring and clamp.
3. Screw in the new Torx screw without tightening it.
Attention! The screw must be easy to screw in. Otherwise, the thread must be passed with a die.
4. Loosen the fuel distribution line mounting bolts. This is necessary to install the injection line without additional force.
5. Secure the injection pipe to the injector with the union nut, without tightening the nuts.
6. Tighten the fuel rail mounting bolts to 14 Nm.
7. Tighten the new Torx clamp screw to 7Nm. Then tighten the screw an additional 90° (½ turn).
8. Tighten the union nuts of the injection pipeline, holding the injector from turning. Tightening torque of a new nut: 20 Nm, of a reused nut: 25 Nm.
Caution! Never exceed the tightening torque. Otherwise, the threaded fitting will not be able to be unscrewed the next time it is loosened.
9. Replace the drain pipe and secure it with a wire clip.
10. Connect the injector connector.
11. Install the engine top covers, refer to Section Removal and installation the top engine cover.