Warning: Handle fuel injectors with extreme caution. Never place your hands or any other body parts under the nozzle jet, as the high operating pressure may cause the fuel jet to penetrate the skin, resulting in fatal injuries. It is strongly recommended that all work involving pressure testing of injectors be performed by a fuel injection system specialist or dealer.
Examination
1. Injectors wear out with long-term use, and it is reasonable to expect that they will need repair or replacement after 100,000 km. A precise check of the serviceability, overhaul and calibration of the injectors must be entrusted to a specialist. A defective injector, which may be the cause of detonation or smoking, can be identified without disassembling as follows.
2. Start the engine, set it to fast idle mode. Gradually loosen the coupling on each injector one at a time. Once the coupling on the faulty injector is loosened, the detonation or smoking should stop.
Removal
3. Carefully clean the area around the injectors and injector tube connecting nuts.
4. Disconnect the outlet pipes from the injectors (see illustration).
16.4. Disconnect the outlet tubes from the top beer nozzles.
5. Unscrew the connecting nuts securing the injector tubes to the high-pressure fuel pump. Cover open couplings to prevent dirt from entering.
6. Unscrew the nuts and disconnect the tubes from the injectors (see illustration).
16.6. Disconnect the fuel lines from the injectors.
If necessary, the tubes can be removed completely. Note the location of the brackets attached to the tubes. Cover the ends of the nozzles to prevent dirt from entering.
7. Unscrew the injectors using a deep socket or open-end wrench (27 mm) and remove them from the cylinder head (see illustrations).
16.7a. Fuel injector in section: 1 - Fuel injector; 2 - Copper washer; 3 - Bushing; 4 - Sealing fireproof washer; 5 - Glow plug.
16.7b. Unscrew the injectors...
16.7 sec....and remove them from the cylinder head.
8. Remove the copper washers and fire washers from the cylinder head. Also remove the bushings if they are loose (see illustrations).
16.8a. Remove the copper washers...
16.8b....and sealing fireproof washers.
Installation
9. Purchase new copper and fire washers. Also replace the bushings if they are damaged.
10. Try not to drop the nozzles. Also, do not clamp them in a bench vise.
11. Begin installation by inserting the bushings (if deleted) into the cylinder head. Install new fire washers into the cylinder head. Please note that these washers must be installed with the convex side down (to the cylinder head) (see illustration).
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16.11. Orientation of the fireproof washer during installation: A - Early modification washer - convex side up; C - Late modification washer - convex side down.
12. Install new copper washers into the cylinder head.
13. Insert the injectors and tighten them to the specified tightening torque Specifications.
14. Install the injector tubes and tighten the connecting nuts securely. Place the clamps on the tubes as marked before removal.
15. Connect the drain pipes.
16. Start the engine. If this fails, bleed the fuel system, see Chapter 7.