Removing
Switch off ignition and disconnect a wire from the negative plug of the storage battery.
Remove the integrated air supply system.
Disconnect the electrical connectors from the injectors.
Disconnect the fuel return pipes from the injectors. Seal the fuel return pipes with suitable plugs to prevent dirt from entering.
Use SODIMAC 35 to clean the union nuts of the high pressure fuel pipes and the area around the nuts.
Pic. 4.35. Location of fuel supply pipelines to injectors: 1, 2, 8 - connecting nuts; 3 - high pressure fuel pipe; 4 - connecting nut; 5 - high pressure fuel pipes; 6 - high pressure sensor; 7 - bolts; 9 - fuel distributor (Common Rail); A - hexagon on the nozzle; B - hexagon on the high pressure fuel pump
Holding the hexagons A with a wrench (pic. 4.35) on the injectors, unscrew the connecting nuts 1 fastening the high pressure fuel pipes 5 to the injectors with the second wrench.
Unscrew the connecting nuts 8 fastening the high pressure fuel pipes 5 to the fuel distributor and remove the fuel pipes. Seal the fuel pipes and fittings on the fuel distribution line with suitable plugs to prevent dirt from entering.
Pic. 4.36. Nozzle: 1 - sealing ring; 2 - spacer; 3 - nozzle; 4 - bolt; 5 - bracket; 6 - sleeve
Remove bolts 4 (pic. 4.36), remove the injector mounting brackets 5 and, being careful, remove the injectors from the cylinder head.
Attention! Do not turn the nozzles on the hexagon A (see fig. 4.36).
Remove O-rings 1 and spacers 2 from injectors.
Close the injector sockets and injector nozzles with suitable plugs.
Installation
Attention! When installing injectors, use new high pressure fuel lines 5 (see fig. 4.35) and o-rings 1 (see fig. 4.36).
Remove the plugs covering the injector sockets.
Install new O-rings on the injectors.
Install the injectors on the cylinder head and secure them with brackets and bolts.
Install the high-pressure fuel pipes on the injectors and the fuel distributor and secure them with connecting nuts, tightening them first with a torque of 17 Nm, and then finally with a torque of 22 Nm. When tightening the connecting nuts on the injectors, hold the hexagons A with a wrench (see fig. 4.35).
Install an integrated air supply system.
Remove the air filter housing.
Connect the wire to the negative battery terminal.
Start the engine.
Check the tightness of the connections.
Increase the engine speed to 3500 min-1.
Check the tightness of the connections.
Install the air filter housing.
Install the decorative cover on the engine.