Note: One pressure plate secures 2 nozzles and can only be removed after removing both nozzles.
Unscrew union nuts for high-pressure fuel lines of injectors -1... 4- and remove corresponding lines. Close open openings of pipelines and fittings with clean plugs.
Remove screw -1- and remove pressure plate. How to remove the injectors: first, the injector of cylinder "2" is removed", then cylinder "1", or cylinder "4", then cylinder "3". Fit puller -T10055- with puller -T10415- as shown in illustration and pull injector up. Before removing the injector, remove the pressure plate.
Note: To avoid damaging the sealing lip, remove the nozzle with a twisting motion.
Place the removed nozzles on a clean cloth.
Installation
Carefully! Risk of damage to the nozzle seat. To remove soot particles from the seating surface, clean the injector chamber in the cylinder head with a cloth soaked in engine oil or corrosion remover -VAS 6811 -.
Installing new nozzles
When installing a new injector, the following must be replaced: copper o-ring, injector seat o-ring, fuel return o-ring. Observe all instructions for installing high-pressure pipes.
Installing used injectors
When installing a previously removed injector, the following must be replaced: copper o-ring, injector seat o-ring, fuel return o-ring. Apply a rust remover to the nozzle tip (from an aerosol can). After about 5 minutes, wipe the particles of soot or oil with a rag. To remove the old copper sealing ring of the injector, carefully clamp it in a vise so that the ring is fixed in a vise, and the injector itself can be rotated between the jaws of the vise. With light rotational and translational movements, remove the nozzle from the copper sealing ring. Clean deposits under the copper O-ring. Replace sealing ring for injector using tool -T10377-.
Continued for used and new injectors
Lubricate all O-rings with mounting oil, engine oil or diesel fuel before installation. Install injectors. Tighten union nuts for high-pressure pipes by hand. Check for tension. After replacing one or more injectors, it is necessary to write the adaptation of the correction codes of the new injectors to the engine control unit. Fill the fuel system with fuel/bleed air from the fuel system.