1 - intake silencer and resonant channel; 2 - injection pipelines; 3 - return fuel line; 4 - nozzles; 5 - gaskets and washers
A bad injector can also be identified by loosening the union nuts one by one while the engine is running at fast idle. If the number of revolutions after loosening one of the nozzles remains unchanged, then this nozzle is faulty. The injector can be checked with a pressure gauge. (Performed in the workshop; required spray pressure: 110 bar).
The first signs of injector failure:
- Misfiring
- Detonation in one or more cylinders
- The engine gets very hot
- Engine power drop
- Excessively strong black exhaust cloud
- High fuel consumption
Removing
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Unscrew intake silencer and resonant channel.
3. Thoroughly clean the outside of the injection lines and fuel return lines with a cold cleaner.
4. Remove the injection pipes as a set; to do this, loosen the union nuts on the injection pump and injectors with a slotted ring wrench.
Attention! Do not change the shape of the bend.
5. Remove the fuel hose from the return pipe and loosen the lock nut, remove the gaskets and the return pipe.
6. Remove the nozzles and arrange them in the order of installation.
Attention! Dirt must not get into the combustion chambers through the holes of the nozzles.
7. Each hole also contains a gasket and washer that must be replaced.
8. Check the nozzle needle for wear and damage, remove soot with a wooden spatula.
Attention! Never treat the nozzle or nozzle needle with wire, a file or sandpaper. Do not confuse the individual elements of the injectors with each other.
Installation
1. Install 4 new gaskets and washers.
Attention! Observe the installation position, the blue mark must point upwards.
2. Install nozzles and tighten with force 65 Nm.
Attention! Overtightening the nozzle holders can result in deformation of the nozzles and jamming of the nozzle needles or other damage.
3. Install the fuel return line with new gaskets and tighten the nuts with force 30 Nm.
4. Install the injection pipes, tighten the union nuts with force 30 Nm.
5. Slightly loosen the union nuts of the injection lines on all nozzle holders.
6. Turn the crankshaft with a starter until fuel comes out of the pipelines. Tighten the pipes to the prescribed torque.
7. Install the intake silencer and resonant channel.
8. Connect the mass cable to the battery.
9. If available, set the clock and set the radio's security code.