Removing and Installing Injection Valves

Removing And Installing Injection Valves

Technical values







Preliminary work

Preliminary work for removing injection valves

1. Disconnect the battery.
2. Remove air cleaner housing.

General warning notes

Danger from fuel

DANGER:
Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

Hot engine components

WARNING:
Risk of injury from hot engine and hot engine fluids.
- Danger: of burns, scalding, damage to skin, injury to the eyes.

- Do not carry out work on the engine while it is hot.

Removing injection valves

Removing injection valves of cylinder bank 1-3

DANGER:
Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

WARNING:
Risk of injury from hot engine and hot engine fluids.
- Danger of burns, scalding, damage to skin, injury to the eyes.

- Do not carry out work on the engine while it is hot.

1. Unclip the two coolant hoses -1 - and aluminium pipe of the brake booster -2- from the holders on the transverse member and carefully lay to one side.







2. Remove plastic lines from holder -3 and 4- and pull off cable plug from switch-over valve -1 -.







3. Open line connections in left of engine compartment.
3.1. Loosen the vacuum lines for the brake booster -1-. For the tandem pump feed line, remove the plastic protection, push the holder forward and pull off the line. Immediately put plastic protection back in place.
3.2. Disconnect tank vent line -2-. In order to do this, press the lugs of the rapid-action coupling and pull off the line (vent line remains fitted -3-).







4. For better access, secure the lines and hoses to one side with a tie-wrap - Plastic lines.







CAUTION:
Material damage through lowering engine
- Cables and coolant hoses can be stretched and torn

- Lower the engine with a jack no more than 40 mm maximum

5. Support the engine with a jack. Unscrew the two collar nuts of the rear engine mounts. Lower the engine by 30 - 40 mm. Should the period between removal and installation be extended, the engine must be lifted back into position and temporarily secured with the collar nuts. Attach an appropriate warning notice.
6. Remove cable duct on the fuel distributor pipe. To do this, pull cable plug from camshaft position sensor -2- and lift up cable duct.







7. Remove cable holder -2-. Remove fastening screws for fuel distributor pipe -1- and pull fuel distributor pipe from the intake distributor.







8. Pull off cable plug for injection valves and release fuel distributor pipe. Push the cable duct to one side.
9. Before opening the fuel lines, put up or attach to vehicle a warning sign in a clearly visible position.







10. Remove sheetmetal clips of the injection valves - Fitting clip and remove the injection valves from the fuel distributor pipe. Ensure that the sealing rings are present. Because of emerging fuel, place a cloth underneath.







11. Check sealing rings and replace if necessary.

Removing injection valves of cylinder bank 4-6

WARNING:
Risk of injury from hot engine and hot engine fluids.
- Danger of burns, scalding, damage to skin, injury to the eyes.

- Do not carry out work on the engine while it is hot.

1. Remove cable duct on the fuel distributor pipe. To do this, carefully lift up cable duct -cable duct-.
2. Pull off cable plug for injection valves and release fuel distributor pipe. Push the cable duct to one side.
3. Remove fastening screws for fuel distributor pipe -1- and pull fuel distributor pipe together with fitted injection valves from the intake distributor. Check sealing rings of injection valves and replace if necessary.







4. Before opening the fuel lines, put up or attach to vehicle a warning sign in a clearly visible position.







DANGER:
Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

5. Remove sheetmetal clips of the injection valves and remove the injection valves from the fuel distributor pipe. Ensure that the sealing rings are present. Because of emerging fuel, place a cloth underneath..







6. Check sealing rings and replace if necessary.

Installing injection valves

Installing injection valves of cylinder bank 1-3

DANGER:
Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

1. Check sealing rings and replace if necessary. Insert injection valves into fuel distributor pipe. Align lugs of injection valves with fuel distributor pipe (pressure pipe) -arrow- and fit the sheetmetal clips. Ensure that the sheetmetal clips engage correctly.










2. Check sealing rings of injection valves, if necessary lubricating with silicone spray or similar to ease fitting. Insert fuel distributor pipe together with fitted injection valves into the appropriate openings of the intake distributor and screw in the fastening screws of the fuel distributor pipe to the intake distributor -1-. Tighten screws

- Tightening torque: 7.5 ftlb.







3. Fit cable holder -2-. Move cable duct into position on the fuel distributor pipe and clip in. Push on cable plug.
4. Fit line connections in left of engine compartment.
4.1. Fit vacuum lines for the brake booster -1-. Press the tandem pump feed line into the holder.
4.2. Connect tank vent line -2-, pressing the rapid-action coupling onto the line (vent line fitted -3-).







5. Fit plastic lines into holder -3 and 4- and fit cable plug onto switch-over valve -1-.







6. Lift engine into position with the car jack and fasten

- Tightening torque: 63 ftlb..

7. Clip the two coolant hoses and aluminium pipe of the brake booster into the holder -1 and 2-.







8. Check that all connections and lines are fitted.

Installing injection valves of cylinder bank 4-6

DANGER:
Fuel can escape when fuel line is disconnected.
- Risk of fatal injury.
- Damage to skin.

- Do not work on fuel system if engine is hot.
- Do not smoke, avoid fire and naked flames.
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.

1. Check sealing rings and replace if necessary. Insert injection valves into fuel distributor pipe. Align lugs of injection valves with fuel distributor pipe (pressure pipe) -arrow- and fit the sheetmetal clips. Ensure that the sheetmetal clips engage correctly.










2. Check sealing rings of injection valves, if necessary applying a thin coat of silicone spray or similar to ease fitting. Insert fuel distributor pipe together with fitted injection valves into the appropriate openings of the intake distributor and screw in the fastening screws of the fuel distributor pipe to the intake distributor. Tighten screws

- Tightening torque: 7.5 ftlb..

3. Move cable duct into position on the fuel distributor pipe and clip in. Push on cable plug.

Subsequent work

Work subsequent to installing injection valves
1. Install air cleaner housing.
2. Connect the battery.