Injector - models with intercooler

INJECTOR - MODELS WITH INTERCOOLER

Service repair no - 19.60.10

Remove

NOTE: No. 1 injector incorporates the needle lift sensor and is covered in a seperate procedure.

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See BODY, Exterior fittings.

3. Loosen clip and disconnect intercooler bottom hose from inlet manifold intake pipe.
4. Remove 2 bolts securing EGR recirculation pipe to inlet manifold intake pipe.
5. Remove bolt securing inlet manifold intake pipe to camshaft cover.
6. Remove 2 bolts securing intake pipe to inlet manifold.
7. Remove inlet manifold intake pipe and discard gasket.
8. Position absorbent cloth around fuel injector to absorb any fuel spillages.

9. Loosen injector pipe union at injector.
10. Disconnect injector pipe from injector and move aside.

CAUTION: To prevent damage to fuel system pipes or components, use two spanners when loosening or tightening unions.

11. Remove fuel return/spill hose banjo bolt from injector and discard 2 sealing washers.

CAUTION: Plug the connections to prevent the ingress of dirt.

12. Remove bolt and collect clamp plate securing injector to cylinder head.
13. Remove injector from cylinder head and discard sealing washer.