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Injection Nozzles, Remove and Install
Caution
Lay aside injection nozzle traverses and injection nozzles in
the correct order on removal to ensure correct allocation on
reinstallation.
 Remove
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Remove camshaft - see operation "Camshaft, Remove and
Install".
Remove upper part of intake manifold - see operation "Intake
Manifold - Upper Part, Remove and Install".
Detach oil leak line from injection nozzle traverse.
Remove fastening bolt (1). Slightly raise injection nozzle
traverse and then withdraw it forwards out of cylinder head.
Disconnect seal ring (2) from fuel injection nozzle.
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Remove
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Screw Adapter KM-931 (2) on injection nozzle.
Install Remover KM-328-B (1) on adapter and withdraw injection
nozzle (3) from cylinder.
Disconnect seal ring (4) from fuel injection nozzle.
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 Clean
Clean all removed parts.
Inspect
Check all removed parts for wear and replace if necessary.
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Install
Attach new rubber seal ring (1) and new copper seal ring (3) to
injection nozzle.
Insert injection nozzle in cylinder head - ball (2) must seat in
the recess (4) in the cylinder head.
Fit new rubber seal ring (5) to injection nozzle traverse.
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Caution
To prevent damage to gasket, it is essential that KM-6318 is
used.
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Install
Position KM-6318-2 (2) above 2nd camshaft bearing (3) - ensure
that the sliding surfaces (4) are facing the engine timing
side.
Attach KM-6318-1 (1) to the 2nd camshaft bearing - make sure
that the bores (7) of the camshaft bearings and bolts (5) of
KM-6318-1 match up correctly. The stop (6) must be located on the
transmission side of KM-6318-1. Slide KM-6318-2 (2) in direction of
arrow until stop bears against KM-6318-1.
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Install
Apply a thin coat of silicone grease (white) to new seal ring
(1).
Carefully insert injection nozzle traverse of cylinders 1 and 2
until it bears against cylinder head (arrow) - if necessary assist
the process by tapping lightly with a plastic hammer.
Caution
Ensure that no dirt gets into the injection nozzle traverse as
this can result in operating faults.
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Remove
Slide KM-6318-2 (3) in direction of arrow, detach KM-6318-1 (2)
from 2nd camshaft bearing and remove KM-6318-2.
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Note: Repeat the
installation of the injection nozzle traverse with KM-6318 on
cylinders 3 and 4.
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Caution
Only by following the tightening procedure described below can
it be guaranteed that the injection nozzle traverse is correctly
attached to the injection nozzle.
Install
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Insert traverse injection nozzle with new fastening bolt:
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I
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with Torx nut and extension (without toggle or ratchet) hand
tighten fastening bolt,
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II
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and then turn further by 360°.
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Attach new oil leak line to injection nozzle traverse.
Install upper part of intake manifold - see operation "Intake
Manifold - Upper Part, Remove and Install".
Install camshaft - see operation "Camshaft, Remove and
Install".
Caution
Bleed fuel system with KM-948 once it has been opened.
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