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