Tightening torques | |
Injector flange bolt | 28 Nm |
Nuts for fixing the fuel distribution ramp | 28 Nm |
Nuts for fastening the high pressure fuel lines connecting the fuel rail and injectors | 24 Nm |
Nuts for fastening the neck and oil dipstick on the fuel distribution rail | 21 Nm |
Nozzles can be replaced one at a time.
Removing
Disconnect the battery.
Remove:
- engine top cover
- air filter housing.
Loosen the nuts (1) oil dipstick and neck.
Put the phone aside (2) oil dipstick.
Disconnect:
- glow plugs (3),
- nozzles (4),
- connectors (5) injection pump,
- drain fuel line connecting the injectors to the injection pump.
Clean the fuel supply and return lines.
Disconnect the fuel supply and return lines (6).
Install the plugs on the holes.
Disconnect:
- pressure meter (7) from the fuel rail
- block of wires from the accelerometer sensor (8).
Loosen engine wiring (9) and take it aside.
Remove the neck (10) on the fuel rail.
Remove the high pressure fuel lines between the rail and injectors.
Install the plugs on the holes.
Remove the injector flange bolt (11).
Note: When reusing a diesel engine injector, be sure to mark it as belonging to the cylinder.
Remove diesel injector (12).
Note: If the diesel engine injector is blocked, use the tool to remove it.
Remove the flame arrestor.
Note: Use a tool to block the flame washer at the bottom of the nozzle well.
Removing the injectors using tools Mot. 921-01 and Emb. 830
(A) Injector body removal tool (Mot. 92101).
(B) Inertial puller (Emb. 880).
Install the tool in the puller
Apply a penetrating agent around the nozzle.
Install the inertial puller in the nozzle.
Remove the blocked nozzle with an inertial puller.
Installation
Be sure to replace the flame washer in the appropriate injector well.
Parts cleaning
Attention! It is strictly forbidden to clean the nozzles:
- metal brush,
- sandpaper,
- ultrasound.
Be sure to clean the seat of the removed nozzle.
In case of reusing a removed injector: clean the injector with an injection system cleaning cloth impregnated with injector cleaner or brake cleaner.
If necessary, leave the nozzle soaked in nozzle cleaner.
Wipe the injector with a new injection system wipe.
Attention! For any operation, remove the plugs immediately before installing the part in place.
Note: If one or more injectors are replaced, the alphanumeric code must be registered (C2I) injectors and the number of the cylinder in which it is installed.
Install the flange nozzle.
Torque tighten the injector flange mounting bolt (28 Nm).
Install high pressure fuel lines.
Torque tighten the rail mounting nuts (28 Nm).
Torque tighten the nuts for the high pressure fuel lines connecting the rail and injectors in the order shown (24 Nm).
Install the chute located on the fuel distribution rail.
Attach the engine wiring harness to the neck.
Attach:
- block of wires from the accelerometric sensor,
- block of wires from the pressure sensor in the fuel distribution rail,
- drain fuel line connecting the injectors to the injection pump,
- supply and drain fuel lines to high pressure fuel pump,
- block of wires from injection pump,
- injectors,
- glow plugs.
Install the oil dipstick tube.
Torque tighten the filler neck and dipstick nuts on the fuel rail (21 Nm).
Install:
- air filter housing,
- engine top cover.
Connect the battery.
Perform Alphanumeric Code Programming (C2I) (13) replaced injector or injectors with the scan tool.
Start the engine.
Check for fuel leakage.