Fuel Injection Nozzle / Fan Motor / Pressure Equalizer, Replacing
Fuel injection nozzle / fan motor / pressure equalizer, replacing
Removing the fuel injection nozzle, blower fan motor and pressure equalizer
The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Remove:
- the heater. See Engine coolant heater, replacing Engine Coolant Heater, Replacing
- the nut and the cover.
Remove the control module. See Control module engine coolant heater, replacing Service and Repair.
Remove:
- the hose clamp from the intake hose
- the three screws from the fan shroud. Lift the fan shroud.
Disconnect the fan motor connector.
Disconnect the flame sensor from the mounting.
Fan and combustion chamber
Remove the glow plugs. See Replacing the glow plugs of the engine coolant heater Service and Repair.
Insert a round object in the hole for the glow plug and press downwards so that the combustion unit is lifted up.
Note! Take care not to damage the thread, the edge or the nozzle unit.
A damaged nozzle unit can cause imbalance (combustion noise) and interruptions in the function. To avoid this it is important that an object with as large a diameter as possible is used. Do not insert the object too far.
Combustion chamber
Release the combustion chamber: Slacken off the 3 screws from the mounting.
The engine mounting and blower fan motor (and holder) internal location is determined by a lug in the engine mounting. These can only be installed in one position.
Fuel injection nozzle, atomizer and outer nozzle head
Remove the screw holding the atomizer to the fan motor spindle.
Note! Do not use the fan wheel as a counterhold when slackening off screws. This could damage the fan wheel.
Remove:
- the atomizer
- the spacer
- the outer nozzle head
- the fuel injection nozzle.
Note! Take care of the spacers and washers (1) and note their internal order.
Blower fan motor and motor mounting
Remove the 3 screws between the engine mounting and the other mounting.
Remove the mounting and the fuel line.
Remove the engine mounting.
Note! Note the position of the engine mounting in relation to the fan motor. It is vital that the engine mounting is correctly installed.
Pressure equalizer with fuel line
Open the mountings around the fuel line: Tap them carefully using a mallet and a screwdriver. Only open the mountings just enough to remove the fuel line.
Remove the pressure equalizer and the fuel line.
Installing the fuel injection nozzle, blower fan motor and pressure equalizer
Pressure equalizer with fuel line
Install the new pressure equalizer and fuel line.
Note! It is important that the fuel line is in contact with the bottom of the motor mounting. Also ensure that its connector is in contact with the bottom of the cut-out on the mounting.
Squeeze the mountings into place around the fuel line using a pair of pliers.
Blower fan motor and motor mounting
Install:
- motor holder on a new motor
- the motor on the motor mounting. Tighten to 2 Nm. Use thread sealant.
The fuel line must be lined up with the fan motor joint.
Fuel injection nozzle, atomizer and outer nozzle head
Install the fuel injection nozzle with washer (1).
Note! Gasoline and diesel versions have different fuel injection nozzles.
Install:
- the outer nozzle head
- a conical spacer with the cone pointing towards the outer nozzle head
- the atomizer
- a new screw with all components on the shaft of the blower fan motor. Tighten to 3 Nm. Use thread sealant.
Heat exchanger and glow plug
Install the combustion chamber.
Assemble the fan shroud with the combustion unit and the heat exchanger.
Center the socket for the glow plug in the flame shield with the mounting on the heat exchanger.
Position the glow plug in the heat exchanger.
If the glow plug can be screwed in by hand the glow plug socket has been centered correctly. Tighten the glow plug. Tighten to 15 Nm.
Finishing
Connect the connector to the blower fan motor. The cables must be routed under the nozzle pipe.
Install the flame sensor.
Note! Ensure that no cables are routed under the flame sensor.
Install:
- the fan shroud using three screws
- the cover with the nut (see the illustration). Tighten to 2 Nm
- the heater. See Engine coolant heater, replacing Engine Coolant Heater, Replacing.