Table of contents: Engines 3.0 l 1st generation ↓ 3.0L SCR engines ↓ Engines 3.0 l 2nd generation ↓ 4.2L engines ↓
Engines 3.0 l 1st generation
1. The installation details of the injectors and pressure fuel lines are shown in the illustration.
7.1. Installation details of injectors and pressure fuel lines for 3.0L 1st generation, 3.0 SCR and 4.2L engines (with the BTR code):
1 - Copper seal, replaceable;
2, 14 - Sealing ring, subject to replacement;
3 - Injectors;
4 - Flange nut for part 16, 10 Nm;
5 - High pressure pipes to the injectors;
6 - Fuel distribution line;
7 - Gasket, subject to replacement;
8 - Hollow bolt, 25 Nm;
9 - Connecting piece;
10 - High pressure pipe from the fuel injection pump. 25 Nm;
11 - High pressure pipe between fuel distribution lines, 25 Nm;
12 - Bolt, 22 Nm;
13 - Fuel return lines, do not disassemble, replace only together with the pressure holding valve;
15 - Injector housing bolt, 5 Nm;
16 - Nozzle retaining part; reinstallation is only permitted with the same injector in the same place; is replaced together with the nozzle.
The following description is given using the left side as an example. On the right side, the actions are similar, except for some procedures that do not need to be performed. Before removing the injectors on the right side, the air hose and air cleaner cover must be removed.
2. Remove the upper engine cover (see Section 19 of Chapter 1).
3. Disconnect the vacuum line (2 in illustration 4.12a of Chapter 2), going to the vacuum receiver.
4. Prepare a cloth to collect the fuel. Disconnect the fuel supply hose from the fuel filter (6 in illustration 4.13 of Chapter 2) and disconnect the fuel hose going to the fuel cooler at connections (3 and 5). Unscrew the bolts (1 and 2) and remove the nut (4). Move the filter to the side without disconnecting the remaining fuel lines.
5. On BUG/BUN engines, remove the air hose (arrows in illustration 4.16 Chapter 2) and disconnect the connector (6) of the throttle module "J338" (bottom). Then unscrew the bolts (1-4 in illustration 4.4) and remove the inlet connecting pipe together with the "J338" module.
6. On CASA/CASB engines, loosen the clamp (3 in illustration 4.15) and remove the air hose. Unscrew the bolt (2), disconnect the connector (4) and remove the "J338" module (5).
7. Remove the bolts (1, 2, 4 in the illustration) and remove the intake manifold bracket from the cylinder head.
7.7. Bolts (1, 2, 4) of the inlet connecting pipe bracket.
8. Lift and turn the locking tab counterclockwise (1 in illustration 11.1e of Chapter 2) to remove the oil filler neck.
9. Remove the wiring bracket from the cylinder head cover (5 in illustration 11.3 of Chapter 2), disconnect the connectors (1-4) of the fuel distribution line and injectors, move the wiring to the side.
10. Disconnect the return lines from the injectors. To do this, press on both locking tabs and simultaneously pull the central part up (see illustration).
7.10. Separating the return line from the injector.
11. Remove the union nuts (1-6 in the illustration) and remove the high pressure pipes of the injectors.
7.11. Union nuts for fuel injector pipes.
12. Unscrew the fasteners of the injector housings (see illustration).
7.12. Fastening of injector housings.
Pull the covers up and rotate them 90°.
13. Loosen the fasteners of the retaining parts (see illustration).
7.13. Fastening of retaining parts.
14. Remove the injectors using the tools shown in the illustration.
7.14. Removing the injector.
Seal any open holes to prevent dirt from getting in. If the injectors are to be reinstalled, mark them so that they can be returned to their original locations.
15. Before installing the injector, replace its copper seal, the sealing ring of the mounting well and the sealing ring of the connection with the return line. If a new injector is installed, use a new retaining piece as well. Pre-lubricate the O-rings with engine oil. Fuel pressure pipes can be reused if they are free of corrosion, their flow is not impaired, and there are no cracks or signs of deformation on their conical ends.
16. Installation is carried out in reverse order. After replacing at least one injector, the voltage and fuel delivery calibration values specified on the corresponding injectors must be entered into the ECM for the new injectors (see illustration).
7.16. Calibration code on the injector.
Finally, let the engine idle for a few minutes.
3.0L SCR engines
17. The installation details of the injectors and pressure fuel lines are shown in Figure 7.1. Further description is given using the left side as an example. On the right side, the actions are similar, except for some procedures that do not need to be performed. Before removing the injectors on the right side, the air hose and air cleaner cover must be removed.
18. Remove the upper engine cover (see Section 19 of Chapter 1).
19. Disconnect the return lines from the injectors. To do this, press on both locking tabs and simultaneously pull the central part up (see illustration 7.10). Disconnect the connectors of the injectors to be removed.
20. Loosen the union nuts of the fuel pressure pipes (1 in the illustration) on the injectors and union nuts of the pressure fuel pipes (2) on the fuel distribution line.
7.20. Nuts of pressure fuel pipes going to injectors.
21. Follow the steps described in paragraphs 12-16.
Engines 3.0 l 2nd generation
22. Details of installation of injectors and pressure fuel lines are shown on illustrations 1.3c. The following description is given using the left side as an example.
23. Remove the upper engine cover (see Section 19 of Chapter 1) and the air cleaner cover (see Section 16 of Chapter 1).
24. Disconnect the injector connectors (arrows in the illustration) and the fuel pressure control valve "N276" (1).
4.24. Connectors of injectors (arrows) and valve "N276".
Remove the cylinder head and fuel rail wiring.
25. Disconnect the return fuel hoses from the injectors. To do this, press on both locking tabs and simultaneously pull the central part up (see illustration).
4.25. Disconnecting the return hose from the injector.
26. Remove the union nuts (2-4 in the illustration), remove the pressure tubes and seal the openings to prevent dirt from getting into them.
4.26. Fastening of pressure fuel pipes.
27. Mark the position of the retaining piece (1 in the illustration) regarding the injector for reinstallation.
4.27. Injector holder bolt.
Unscrew the bolt (2) and remove the retaining part. Repeat these steps for other injectors.
28. Remove the injectors using the tools shown in the illustration.
4.28. Removing the injector.
Seal any open holes to prevent dirt from getting in. If the injectors are to be reinstalled, mark them so that they can be returned to their original locations.
29. Follow the steps described in paragraphs 15-16.
4.2L engines
30. Details of the installation of injectors and pressure fuel lines are shown in Figure 7.1 (for the BTR engine) and in the illustration (for CCFA/CCFC engines).
7.30. Installation details of injectors and pressure fuel lines for 3.0L 1st generation, 3.0 SCR and 4.2L engines (with the BTR code):
1 - Copper seal, replaceable;
2, 14 - Sealing ring, subject to replacement;
3 - Injectors;
4 - Flange nut for part 16, 10 Nm;
5 - High pressure pipes to the injectors;
6 - Fuel distribution line;
7 - Gasket, subject to replacement;
8 - Hollow bolt, 25 Nm;
9 - Connecting piece;
10 - High pressure pipe from the fuel injection pump, 25 Nm;
11 - High pressure pipe between fuel distribution lines, 25 Nm;
12 - Bolt, 22 Nm;
13 - Fuel return lines, do not disassemble, replace only together with the pressure holding valve;
15 - Injector housing bolt, 5 Nm;
16 - Nozzle retaining part; reinstallation is only permitted with the same injector in the same place; is replaced together with the nozzle.
The following description is given using the left side of the BTR and CCFA engines as an example. The steps are similar for the CCFC engine.
31. Remove the upper engine cover (see Section 19 of Chapter 1) and the air cleaner cover (see Section 16 of Chapter 1).
32. Remove the bolts (1 and 2 in Illustration 44.10 Chapter 2).
33. Unscrew the bolt (2 in illustration 35.22 Chapter 2) and slightly push the coolant pipes to the left.
34. Before removing injectors No. 7 and No. 8, unscrew the bolts (arrows in illustration 35.23 Chapter 2), loosen the nut (3) and move the fuel filter with the connected fuel hoses (1 and 2) to the side.
35. Remove the oil filler neck by lifting the locking tab and turning it clockwise (see illustration).
7.35. Removing the oil filler neck.
36. Disconnect the return fuel hoses from the injectors. To do this, press on both locking tabs and simultaneously pull the central part up (by analogy with illustration 7.25).
37. Remove the union nuts (2-5 in the illustration), remove the pressure tubes and seal the openings to prevent dirt from getting into them.
7.37. Union nuts (2-5) of pressure pipes.
38. Unscrew the fasteners of the injector housings (by analogy with illustration 7.12). Pull the covers up and rotate them 90°.
39. Loosen the fasteners of the retaining parts (by analogy with illustration 7.13).
40. Remove the injectors using the tools shown in Figure 7.14 (for front cylinders) or in the illustration (for rear cylinders).
7.40. Removing the rear cylinder injector.
Seal any open holes to prevent dirt from getting in. If the injectors are to be reinstalled, mark them so that they can be returned to their original locations.
41. Follow the steps described in paragraphs 15-16.
(Information obtained from this resource AUDIMANUAL.RU)