Contents: Removal ⬇ Installation ⬇
Removal
1. Remove the upper decorative engine cover.
2. Remove the soundproofing coating.
3. Pull the return fuel line hose clamp upward (arrows) as shown in the figure below.
4. Disconnect the wiring harness connectors (arrows) from the glow plugs as shown in the figure below.
Note: Fuel injectors are secured in pairs using a special mounting clamp.
5. Loosen the connecting nuts of the high-pressure fuel pipes (1...4), then pull and disconnect the high-pressure fuel pipes, as shown in the figure below.
6. Seal all open passages and pipes of the fuel system with suitable plugs.
7. Unscrew the fastening screw (1) and remove the fastening clamps, as shown in the figure below. First of all, you need to unscrew the mounting screw above the second cylinder, then above the first, then above the fourth and above the third, respectively.
8. Install the special puller (T10055) together with the adapter (T10415), as shown in the figure below. Remove the fuel injector using a special tool.
9. First remove the fuel injector clamps.
Note: To avoid damaging the sealing surfaces, the fuel injector must be removed using a rotating motion.
10. Place the fuel injectors on a clean, lint-free cloth.
Installation
Caution: There is a high risk of damage to the fuel injector sealing surface.
Installing a new fuel injector
When installing a new fuel injector, the following components must be replaced:
- Copper ring.
- Fuel injector sealing ring.
- O-ring under the fuel supply pipe.
Installing a previously removed fuel injector
When reusing a fuel injector, the following components must be replaced:
- Copper ring.
- Fuel injector sealing ring.
- O-ring under the fuel supply pipe.
1. Spray the end of the fuel injector nozzle with a special anti-corrosion solvent. Remove any remaining motor oil and carbon deposits from the surface after 5 minutes.
2. Remove the old copper sealing washer from the pump (plunger) sections; to do this, carefully clamp the copper sealing washer in a vice until it just stops turning. Then you should carefully pull out the pump (plunger) section by lightly turning it by hand from the copper sealing washer. Before proceeding with the installation, the cleanliness of the pump should be checked (plunger) sections and assembly points.
Sequence of operations during assembly
Note:
- All O-rings must be lubricated with engine oil before installation.
- Before proceeding with installation, you should carefully check the cleanliness of all parts and assembly areas.
1. To remove soot from the sealing surface of the pump (plunger) the sections in the cylinder head should be cleaned with engine oil or a rag soaked in rust solvent.
Caution: Do not damage the sealing surfaces.
2. Install on the high pressure fuel pump section (injection device) new copper sealing washer using a plastic sleeve.
3. Replace the O-ring seal for the high pressure fuel pump section hole (injection device) in the head, for this you should use the installation tool (T10377).
4. The new O-ring should be lubricated with oil and carefully pushed onto the fuel return line connection.
Attention:
- Proceed with extreme caution to prevent unnecessary assembly work or subsequent damage.
- It is necessary to prevent damage and contact between sections of the high-pressure fuel pump (injection devices) with cylinder head.
5. Always introduce 2 sections of the high-pressure fuel pump (injection devices) with a common clamping bar carefully into the hole in the cylinder head, observing their position for assembly.
6. Screw in the new clamp bar mounting bolt, tighten it only slightly, applying the required tightening torque, not exceeding 1-2 Nm.
Note: To install the high pressure line without internal stress, it is necessary to be able to align the position of the high pressure fuel pump section (injection device) turning the last one.
7. Install the high-pressure line without internal stress; to do this, align the position of the high-pressure fuel pump section (injection device) turning the last one. The union nuts should be tightened by hand only.
8. Tighten the clamp bar fixing screw.
9. Tighten the union nuts of the high-pressure lines.
10. Carefully press the return fuel line connection through the sealing ring onto the high-pressure fuel pump section. The bolt should enter the locked position with a characteristic click.
11. Then you should carefully press the locking bolt downwards.
Note: After replacing one or more pump (plunger) sections (injection devices) it is necessary to carry out adaptation in accordance with their codes of "equalization of the amount of fuel injected IMA" and "equalization of the voltage ISA".
12. Fill the fuel system.
