Replacing injection valves
Spezialwerkzeugliste: |
- KM-6326-1
- KM-6359
- KM-6360
- KM-6364
- KM-796-A
- KM-807
- KM-J-34730-91
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Note: When working on
the fuel system, cleanliness must be strictly observed as even
small particles of dirt can lead to faults in the engine or fuel
system. The injectors may only be removed with the engine cold and
with unequivocal diagnosis.
Remove
4. |
Remove air intake pipe (2)
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5. |
Detach engine vent valve
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6. |
Remove engine control unit
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7. |
Remove wiring harness for engine management
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Release and disconnect 2x wiring harness plug
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Fuel pressure sensor (high pressure), fuel pressure regulator
(high pressure)
Note: Wiring harness
plug is disconnected if injectors remain in cylinder head
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8. |
Release fuel pressure
Warning: Comply with safety
regulations and national legislation.
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Use KM-J-34730-91
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Unscrew protective cap from test connection
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9. |
Detach fuel line (1)
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Seal fuel line and fuel rail
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10. |
Remove fuel connection line (2)
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Seal fuel line, fuel rail and high pressure fuel pump
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11. |
Detach high pressure fuel line (3)
Warning: Collect emerging fuel.
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Unscrew 2x union nuts
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High pressure pump, fuel rail
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12. |
Detach wiring harness bracket
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Release and disconnect 3x wiring harness plug
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Tank vent valve, intake pipe pressure sensor, channel switch
control motor
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13. |
Undo fuel rail
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Detach bracket
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Unscrew 2x stud bolt (1)
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14. |
Remove fuel rail
Note: In the case of
injectors located in the cylinder head, remove injectors from
cylinder head (using KM-6360 ).
Important: Do not jam fuel rail
when pressing it off.
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Use KM-6359
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16. |
Detach injector wiring harness
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17. |
Detach fuel injector
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Detach spring clamp, retaining clamp (plastic)
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Important: Only injector nozzles
with the same part numbers are to be incorporated.
Important: Use a
soft brass brush. Brush with brass brush in one direction only. Do
not touch injector outlet.
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Clean valve body
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Install
18. |
Replace 4x combustion chamber seal ring (1)
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Cut combustion chamber seal ring
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Important: Do not damage metal
surface.
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Pull open combustion chamber seal ring (1) on slip-on drift
Note: Place slip-on
drift on injector and push combustion chamber seal ring with
cylindrical side of mounting sleeve KM-6364 onto injector up to the groove. Smooth
combustion chamber seal ring with conical side of mounting sleeve
by lightly turning. Leave mounting sleeve attached.
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19. |
Replace injector seal ring
Note: To protect the
injector outlet and condition the combustion chamber seal ring,
KM-6364 remains attached until
immediately before installation in the fuel rail.
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Clean 4x sealing surfaces
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Fit thrust ring using slip-on drift
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20. |
Attach fuel injector
Note: Press in injector
with circling movements. Do not use lubricant, must be easy to
fit.
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Attach spring clip
Note: Spring clip must
audibly engage.
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Attach retaining clamp (plastic)
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Replace retaining clamp
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21. |
Attach injector wiring harness
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Connect and lock 6x wiring harness plug
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4x injector, fuel pressure sensor (high pressure), fuel
pressure regulator (high pressure)
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22. |
Install fuel rail
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Clean contact surface in cylinder head using compressed air
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Carefully insert fuel injectors
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Important: The bolts must be
tightened twice according to the tightening sequence. Tighten bolts
from inside to outside.
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Tighten 4x bolt 4 Nm + 8 Nm
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Attach bracket
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Align retaining shackles
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Tighten 2 stud bolts 8 Nm
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23. |
Install wiring harness bracket
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Connect and lock 3x wiring harness plug
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Tank vent valve, intake pipe pressure sensor, channel switch
control motor
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24. |
Attach high-pressure fuel line
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Tighten 2x union nuts 25 Nm
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25. |
Attach fuel connection line
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27. |
Attach wiring harness for engine management
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Connect and lock combination plug
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29. |
Attach engine control unit
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30. |
Install air intake pipe.
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Tighten 2x clamp 3.5 Nm
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33. |
Fuel System, Check for Leaks
Important: Wear protective
goggles and protective gloves.
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Start engine.
Note: Check fuel system
for escaping fuel.
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35. |
Program volatile memories
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