Fuel injectors

Operation 1060F10 · Injectors and lines

Removing

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal.

Carry out - 1060G22 cam angle sensor - r r.

1. Disconnect the electrical connections from the injectors.

2. Undo the bolts (2a) and move the electrical wiring (2b) aside.

Removing

Proceed with the removal - 1044B10 fuel filter assembly - r + r or replace.

Proceed with the removal - 1080C24 e.g.r. system solenoid - r + r.

Proceed with the removal - 1060F50 fuel return manifold - r r.

Proceed with the removal - 1060F36 lines to injectors - r r.

1. Undo the nuts (1a) and the bolts (1b) and remove plate (1c) connecting the timing side rigid engine mount to the air chamber.

1. Push clips (1a) by hand and disconnect the pipe from the injectors to the fuel manifold (1b), injectors side.

2. Undo the bolts (2a) and move aside the pipe carrier channel (2b) as far as necessary.

3. Undo the connectors (3a) and remove the pipes from the fuel manifold to the fuel injectors (3b).

Use new pipes from from fuel manifold to injectors upon reassembly.

1. Push springs (1a) by hand and disconnect the pipe from the injectors to the fuel recovery manifold (1b), injectors side and remove it.

2. Disconnect the electrical connections from the injectors.

1. Undo the injector mounting bracket nut.

2. Remove the washer (2a) and tapered washer (2b).

3. Fit the injectors (3a), one at a time, using tools (3b) and (3c).

If the same injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted.

If new fuel injector(s) are fitted, the self-learning procedure with the Examiner must be carried out.

Remove the fuel injectors complete with bracket.

Replace the fuel injector copper rings.

Repeat the above procedure to remove the remaining pair of injectors.

4. Remove the fuel injector sealing rings from the upper head.

These sealing rings must be replaced whenever they are removed.

1. Undo the injector bracket nuts.

Refitting

Refit in their seatings the new fuel injector sealing rings on the top head.

1. Place the injectors (1a), complete with brackets (1b), in their seats.

Before refitting, replace the copper seal on the injectors.

2. Refit in their seatings the tapered washer (2a) and the washer (2b).

3. Tighten the nut fixing the injector mounting bracket to the recommended torque.

1. Remove the fuel injectors (1a) complete with brackets (1b) with the tool (1c).

2. Remove the injector bracket support pads.

1. Fit the new pipes from the fuel manifold to the injectors and secure them using the connectors without tightening them.

2. Tighten the connectors for the pipes from the fuel manifold to the injectors, injector side, to the recommended torque using a suitable spanner.

3. Tighten the connectors for the pipes between the fuel manifold and the injectors, fuel manifold side, to the recommended torque using a suitable spanner.

Clean the threaded seats for the above-mentioned pipe on the manifold and the injectors using heptane.

4. Refit in its seating the pipe carrier channel (4a) and secure it with its bolts (4b).

5. Connect the pipe from the fuel injectors to the fuel manifold, fuel injectors side, pushing it until the clips can be heard clicking into place.

Refitting

Refit the fuel injectors in their seatings.

Refit the fuel injector brackets in their seatings with the mounting pads and tighten the nuts to the specified torque.

Connect the electrical connections to the injectors.

Position the connectors for the pipe from the injectors to the fuel recovery manifold on the corresponding injector seats and fully insert them until the click of the spring is heard.

Place the timing side rigid mount connection plate to the air chamber back in its housing and tighten the nuts and bolts.

Proceed with the refitting - 1060F36 lines to injectors - r r.

Proceed with the refitting - 1060F50 fuel return manifold - r r.

Proceed with the refitting - 1080C24 e.g.r. system solenoid - r + r.

Proceed with the refitting - 1044B10 fuel filter assembly - r + r or replace.

Place the electrical wiring back in its seating and fix it using the bolts.

Connect the electrical connections from the fuel injectors.

Carry out - 1060G22 cam angle sensor - r r.

Connect the battery negative terminal.