Fuel Injector: Service and Repair

Injector/pulse damper, replacement

Preparation
Empty the fuel injection system according to Fuel system pressure release Service and Repair.




Remove the charge air pipe over the engine. Seal the openings




Remove the cover over the fuel rail.
Disconnect the injector connectors.
Blow clean around the injectors.
Remove the mounting screws from the fuel rail.
Open the fuel line's quick-release connector using tool 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298).
Spray universal oil or similar around the injector terminals on the intake manifold.
Gently work the fuel rail and injectors loose.

Note! Handle the injector valves carefully to avoid damaging the injector valves' nozzles with needles.

Removing injectors

Remove
- the screws holding the mounting rail to the fuel rail
- the mounting rail
- the injector.

Removing the pulsation damper

Remove
- the screws holding the mounting rail to the fuel rail
- the mounting rail
- the pulsation damper.

Installing injectors
Lubricate the injector O-ring with a thin layer of petroleum jelly.
Install the new injector.

Installing the pulsation damper
Lubricate the new pulsation damper O-ring with a thin layer of petroleum jelly.
Install the new pulsation damper.

Finishing
Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimetres to install the rail.
Tighten the mounting rail to the fuel rail. Tighten to 6 Nm.




Lubricate the injector O-rings with petroleum jelly.
Depress the fuel rail. Ensure that all injectors sit correctly.
Screw the fuel rail into place. Use new screws. Tighten to 10 Nm.
Connect all the connectors for the injectors.
Press the quick-release connector together until a clicking sound is heard.
Reinstall the cover over the fuel rail.




Remove the seals from the charge air pipe. Reinstall the charge air pipe over the engine.
Start the engine. Check for fuel leakage.