Fuel Injector: Service and Repair

Injector/pulsation damper, replacing

Removal

Preparation

Note! Since the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.




- Depressurize the fuel system acc. to: Fuel system pressure release Fuel System Pressure Release.
- Remove the plastic hoses between the turbocharger (TC) and charge air cooler (CAC) and the air cleaner (ACL) and turbocharger (TC). Place them to one side and seal the openings.

Removing the fuel rail




- Remove the protective cover above the nozzles
- Disconnect the connectors from the injectors
- Remove the mounting screws from the fuel rail
- Spray universal oil or similar around the injector terminals on the intake manifold.




Gently work the fuel rail and injectors loose.

Note! Handle the injectors carefully to avoid damage to fuel nozzles and fuel needles.

Removing injectors

Remove:
- the screws holding the mounting rail to the fuel rail
- the mounting rail
- the injector.

Installation

Installing injectors

Note! For tightening torques, see Specifications, B6324S Tightening Torque.

Lubricate the O-ring for the new injector using petroleum jelly.
Install the injector.

Finishing
- Position the mounting rail
- The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail
- Tighten the mounting rail to the fuel rail
- Press down the fuel rail.

Note! Make sure that all the injectors are installed correctly.




- Screw the fuel rail into place. Use new screws. Tighten to 10 Nm.
- Install all connectors on the injectors
- Press the fuel line quick-release connector together until it clicks
- Install the cover over the nozzles
- Remove the seals. Install the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and the air cleaner (ACL) and turbocharger (TC).