Carefully! Mark the correspondence of the injectors to the cylinders. Re-installation is only permitted on the same cylinder. When working on the injection system, follow the rules for maintaining cleanliness. Immediately close the open connections with the special cover.
Disconnect the return pipes from the injectors by pressing the clamps -1- and -2- down and at the same time pulling the release bolt upwards -arrow-.
Disconnect el. plug connections -arrows- of the injectors. Loosen union nuts on high-pressure lines -1 to 4-.
Unscrew the bolt -1- of the clamping bracket. The clamping bracket remains in the installation position until the adjacent injector is removed. Risk of damage due to distortion of the clamping clamp on the injector. First remove the injector of cylinders 2 and 4, then the injector of cylinders 1 and 3, at the same time remove the clamping bracket. Install the puller -T10055- with the puller -T10415- as shown in the illustration and remove the injector upwards. To avoid damage to the seal. edges, remove the nozzle using rotational movements. Place the removed injectors on a clean rag.
Installation of new injectors
When installing a new injector, replace the following parts: copper seal. ring, seal O-ring for injector socket, seal. ring for return fuel fitting highways.
Note: When reusing high-pressure lines, observe the corresponding cylinder designation. The high pressure lines can be reused after the following checks. Check seal. cone of the corresponding highway for the presence of deformations and cracks. The hole must not be deformed, narrowed or damaged. Corroded lines must not be reused.
Installation of previously used injectors
When installing a previously used injector, replace the following parts: copper seal. ring, seal O-ring for injector socket, seal. ring for return fuel fitting highways. Treat the bottom of the injector with rust remover. After about 5 minutes, remove any rust or oil particles with a clean cloth. If the nozzle is heavily soiled, clean its lower part additionally with a soft brass brush to facilitate removal of the copper gasket (do not allow the brass brush to come into contact with the nozzle sprayer). To remove the old copper gasket from the injector, carefully clamp the gasket in a vice so that it is clamped between the clamping jaws directly when turning. Using light turning and pulling movements of your hand, remove the nozzle from the copper gasket. Use a scraper to clean the deposits under the copper O-ring.
Carefully! To remove soot particles from the injector seal surface, clean the injector seat in the cylinder head with a rag moistened with oil or rust remover. Do not damage the sealing surface.
Replace seal. O-ring for the injector seat using the installation mandrel -T10377-. Install the injectors. Hand-tighten the union nuts of the high-pressure fuel lines without tightening them. Make sure the installation is stress-free. Carefully install the connecting elements of the return lines through the lip seal with pressure onto the nozzle (first check the lip seal for damage). The lock should click into place and then carefully press down the unlocking bolt. After installing 1 or more injectors, it is necessary to enter into the engine control unit "adjustment of fuel quantity (IMA) " And "voltage adjustment (ISA) " for new injectors. Additionally, check all other injectors for "adjustment of fuel quantity (IMA) " And "voltage adjustment (ISA) " and the correctness of the specified adjustment values. If the correct correction values are available in the engine control unit, do not re-enter them under any circumstances. Remove air from fuel. system and perform a leak test. To remove air, do not open the high pressure terminals, air from the fuel. the system is deleted on its own. Let the engine idle for a few minutes and then turn it off again. Turn off the ignition. Check the tightness of all fuel. return line systems and outlets (4 pieces). If the tightness is broken, despite the correct tightening torque, replace the faulty unit. Carry out a test drive with at least one acceleration at maximum load and then check the high pressure circuit again for leaks. Presence of air in fuel. system during a test drive may cause the engine to operate in emergency mode. Turn off the engine and clear the event memory. Continue with the test drive.
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