Removing and Installing Fuel Injectors

Removing And Installing Fuel Injectors

Tools







Technical values







Information

Overview







Preliminary work

1. Disconnect battery.
2. Remove pressure pipe.
3. Remove air cleaner housing.

DANGER:
Risk of engine falling down.
- Danger of fatal injury, material damage.

- Support the engine with the prescribed tool.

4. Lower the engine.
Lower the engine by max. 40 mm.

4.1. Support the engine with a jack and retainer plate P 9592.
4.2. Loosen collar nuts on engine mounting and unscrew. Carefully lower engine using the jack.

General warning notes

Safety instructions when working on the fuel system

WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion

- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapours.
- Attach warning sign in a clearly visible position.

WARNING:
Caustic fluid
- Danger of chemical burns

- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

Removing fuel injectors

Removing fuel injectors - cylinder bank 1-3

Observe safety instructions when working on the fuel system.







1. Attach or mount fire hazard warning sign in a clearly visible position on the vehicle.







2. Remove fuel filter.
3. Disconnect or remove lines on the left of the engine compartment.







3.1. Disconnect line to the carbon canister -2- and remove it.
3.2. Remove coolant ventilation -1- at the tank.
3.3. Disconnect vacuum line -3-.







3.4. Expose lines above the fuel collection pipe.
Unclip the lines from the holders and secure them on the coolant reservoir using a tie-wrap.







4. Remove secondary-air pump.
5. Loosen intake air line at the turbocharger 1-3.
Intake air line cannot be removed.







5.1. Unscrew two M6 screws -arrows- and one M6 collar nut -1-. Disconnect intake air line with retaining bracket.







5.2. Press intake air line out of the bracket in the engine compartment.
5.3. Replace O-ring when assembling and grease with Kluber Syntheso Glep (Part No. 000.043.204.68).







6. Remove oil-filter console.
7. Detach wiring harness and fuel line from the fuel collection pipe.
7.1. Pull cable rail -3- upwards at the fuel collection pipe and press to the side.
7.2. Disconnect cable plug -arrows- at the fuel injectors 1-3.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.







7.3. Detach fuel line -2- (a/f 17 and 19) and unscrew.

8. Remove fuel collection pipe with fuel injectors 1-3.







8.1. Unscrew two M6 screws -13-.
8.2. Detach fuel collection pipe with fuel injectors 1-3 from the intake-air distributor and remove.

9. Remove fuel injectors from the fuel collection pipe.
9.1. Remove spring clamps.
9.2. Pull fuel injectors out of the collection pipe.
9.3. Replace the O-rings before assembling if the fuel injectors are to be reinstalled.

Removing fuel injectors - cylinder bank 4-6

Observe safety instructions when working on the fuel system.







1. Attach or mount fire hazard warning sign in a clearly visible position on the vehicle.
2. Remove rear apron.
3. Remove charge air cooler on right.







4. Remove oil filler neck with holder.
4.1. Remove holder for oil filler neck -7-.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.

5. Detach air conditioning compressor.







5.1. Disconnect fuel line.







5.2. Pull engine compartment temperature sensor -1- out of the rubber holder.







5.3. Unscrew the fuel lines from the fuel cooler.
Counter at the fuel cooler (a/f 14) when unscrewing the union nuts -4-.

5.4. Remove compressor.
Remove three M8 screws -5-. Carefully remove compressor, place to one side together with refrigerant lines (use protective surface). If necessary, secure with a tie-wrap to prevent them from slipping.

6. Remove the engine wire harness to create better access to the fuel collection pipe.







6.1. Cut tie-wrap -arrow-.







6.2. Open round connectors on engine wire harness.
To do this, turn bayonet lock anticlockwise and pull off.







6.3. Unplug cable plug for cylinder 4 ignition coil -1-.
Pull cable plug -2- off the camshaft sensor.

6.4. Pull cable rail upwards from fuel collection pipe -arrow-.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.


7. Detach oil line from the oil tank.







7.1. Loosen oil line -1- from the oil tank -2- using crow foot wrench, a/f 32 Nr.189. Counter with an open-ended wrench (a/f 32) while doing this. Unscrew union nut.
7.2. Press line to one side to remove the fuel collection pipe.







8. Remove fuel collection pipe with fuel injectors 4-6.
8.1. Detach fuel line (a/f 17 and 19).
8.2. Remove two M6 screws -13-.
8.3. Detach fuel collection pipe -2- with fuel injectors 4-6 from the intake-air distributor.
8.4. Disconnect cable plug for fuel injectors 4 6.
8.5. Guide out fuel collection pipe -2- in the direction of travel until it is exposed and can be removed.

9. Remove fuel injectors from the fuel collection pipe.
9.1. Remove spring clamps.
9.2. Pull fuel injectors out of the collection pipe.
9.3. Replace the O-rings before assembly if the fuel injectors are to be reinstalled.

Installing fuel injectors

Installing fuel injectors - cylinder bank 1-3







1. Replace O-rings -11 and 12- on the fuel injectors -9-
1.1. Clean sealing faces with a lint-free cloth and apply a thin coat of silicone spray.
1.2. Fit fuel injectors into fuel collection pipe and secure them using spring clamps.
1.3. Insert fuel collection pipe with fuel injectors fitted into the corresponding openings in the intake-air distributor.
1.4. Fit and tighten M6 fastening screws for the fuel collection pipe -13-.
- Tightening torque: 10 Nm (7.5 ftlb.)

2. Fit fuel line and wiring harness.

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.







2.1. Connect fuel line. Fit and tighten union nut -2- (a/f 17 and 19).
- Tightening torque: 30 Nm (22 ftlb.)

2.2. Connect cable plug -arrows- for fuel injectors 1-3.
2.3. Clip on cable rail -3- at the fuel collection pipe.

3. Fit intake air line for side 1-3.







3.1. Position intake air line in the bracket -arrow- in the engine compartment.







3.2. Fit intake air line together with new O-ring and retaining bracket at the turbocharger flange and press it in. Fit and tighten two screws -arrows- and one M6 collar nut -1-.
- Tightening torque: 10 Nm (7.5 ftlb.)







4. Install secondary-air pump.
- Tightening torque: 10 Nm (7.5 ftlb.)







5. Install oil-filter console.
- Tightening torque: 23 Nm (17 ftlb.)
- Tightening torque: 10 Nm (7.5 ftlb.)

6. Fit lines on left of engine compartment.







6.1. Open tie-wrap and move lines into installation position.







6.2. Insert carbon canister line -2- and connect.
6.3. Connect coolant breather hose -1- to coolant reservoir.
6.4. Connect the vacuum line -3-.







7. Install fuel filter.

Installing fuel injectors - cylinder bank 4-6

CAUTION:
Low load capacity of pipe and line connections.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.







1. Install fuel collection pipe with fuel injectors 4-6.
1.1. Replace O-rings on the fuel injectors.
1.2. Clean sealing faces with a clean, lint-free cloth. Apply a thin coat of silicone spray to the O-rings.
1.3. Insert fuel injectors onto fuel collection pipe -2- and secure them using spring clamp.
1.4. Press fuel collection pipe -2- with fuel injectors 4-6 into the mountings in the intake-air distributor.
1.5. Fit and tighten M6 screws -13-.
- Tightening torque: 10 Nm (7.5 ftlb.)

2. Fit fuel lines.
2.1. Screw fuel line (a/f 17 and 19) onto fuel collection pipe and tighten it.
- Tightening torque: 30 Nm (22 ftlb.)

2.2. Screw fuel line onto pressure regulator and tighten it.
- Tightening torque: 30 Nm (22 ftlb.)

3. Attach cable rail.
3.1. Connect cable plug to the fuel injectors 4-6.
3.2. Connect cable plug for cylinder 4 ignition coil -1-.







3.3. Connect cable plug -2- for hall sender.
3.4. Clip on cable rail at the fuel collection pipe -arrow-.







3.5. Connect engine wiring harness.







Fit round connector onto connector bracket and turn clockwise until it reaches the locking point.

3.6. Secure engine wire harness with tie-wraps.

CAUTION:
Low load capacity of pipe and line connection.
- Damage and leaks at pipe and line connections.

- Always counter at the lines when loosening and fastening them.

4. Fit oil line at the oil tank.







4.1. Fit union nut and secure oil line -1- to the oil tank -2- using crow foot wrench, a/f 32 Nr.189. Counter with an open-ended wrench (a/f 32) while doing this.
- Tightening torque: 60 Nm (44 ftlb.)

5. Fit air conditioning compressor.
5.1. Insert compressor carefully. Position and tighten three M8 screws -5-.
- Tightening torque: 23 Nm (17 ftlb.)

5.2. Connect cable plug for compressor.







5.3. Screw the fuel lines onto the fuel cooler and tighten them.
Counter at the fuel cooler (a/f 14) when tightening the union nuts -4-.
- Tightening torque: 25 Nm (19 ftlb.)







5.4. Insert engine compartment temperature sensor into the rubber holder.







5.5. Secure fuel line.







6. Install oil filler neck with holder.
6.1. Install holder for oil filler neck.
- Tightening torque: 10 Nm (7.5 ftlb.)

6.2. Install oil filler neck.

7. Install right charge air cooler.
8. Install rear apron.

Subsequent work

1. Raise the engine.
Raise the engine to assembly position using a retainer plate P 9592.
Screw in and tighten collar nuts for engine mounting.
- Tightening torque: 85 Nm (63 ftlb.)

2. Install air cleaner housing.
3. Install pressure pipe.
4. Connect the battery.