A defective injector can be identified by loosening the union nuts in succession and at high speed (when the engine warms up). If the number of revolutions does not change after loosening the union nut, this indicates a corresponding defective injector. The injector can be checked with a pressure gauge. (Workshop work; required injection pressure: 135 bar).
The first signs of a malfunction of the nozzle appear as follows:
- false ignitions;
- detonation in one or more cylinders;
- engine overheating;
- reduction in engine power;
- excessively strong black exhaust;
- increase in fuel consumption.
Removing
1. Disconnect the negative ground cable from the battery.
Attention! This erases the contents of electronic storage devices, such as engine defect memory or radio code. Read before disconnecting the battery subsection 2.11.
2. Carefully clean the outside of the injection pipes and fuel outlet pipes with a cleaner or diesel fuel.
3. Remove the injection pipes as a set, for which loosen the union nuts (indicated by arrows) on the pump and nozzles.
Attention! Do not disturb the shape of the tubing bend.
4. Remove the injectors and set aside in the same order as you would have to install.
Attention! Dirt must not enter the combustion chamber through the nozzle openings.
5. Each hole contains a corrugated gasket and washer, which must be replaced.
6. Nozzle needles should not have knocked out and rough landing sites. Remove carbon deposits from the nozzles with a wooden spatula.
Attention! Never handle the nozzle and nozzle needle with wire, needle file or sandpaper. Do not confuse the details of different shapes.
Installation
Attention! Observe installation position.
Attention! Over tightening the nozzles can cause them to deform and thus lead to needle sticking or other damage.
1. Install nozzles (2) and tighten to 65 Nm. Install 4 new wave pads (4) and spacers (3).
2. Install the injection pipes, tighten the union nuts with a force of 25 Nm.
3. Install the fuel outlet pipes with new gaskets and tighten with nuts to 30 Nm.
4. Slightly loosen the union nuts of the injection tubes on all injectors.
5. Turn the engine with the starter until fuel comes out of the injection tubes. Fasten the injection pipes with the prescribed tightening torque.
6. Install the air supply silencer and resonator channel.
7. Connect the negative ground cable to the battery.
8. If you have a clock, set the time and set the radio's security code.