Fuel Injector: Service and Repair

Replacing All Fuel Injectors

Special tools required:
- 13 5 220
- 13 5 281


NOTE: Read out fault memory of EMS2000 control module, check stored fault memory, rectify faults, clear fault memory.


Turn off ignition.


CAUTION!
When working on the oil, coolant or fuel circuit, protect the alternator against contamination.
Cover alternator with suitable materials.






Release retaining clips (1) and gently lift the front of the cover to remove.






Remove cap from injector rail.
Install special tool kit 13 5 220.
Fit a suitable length of hose onto the special tool and route the hose into a suitable fuel container.
Screw in check valve (1) of special tool 13 5 220 to release fuel pressure from injector rail into the fuel container.






Hold absorbent cloth around special tool 13 5 220 and remove hose and special tool.
Refit valve cap.
Remove purge hose from retaining clips (1).






Unclip fuel feed pipe from stabilizer bracket.
Disconnect quick fit connector (1) from injector rail and fit special tool 13 5 281.
Note use of absorbent cloth when disconnecting fuel hose quick fit connector.






Disconnect fuel injector connections (1).
Disconnect knock sensor connector (2) from fuel injector rail.
Move clips (3) to remove engine harness ducting from fuel rail brackets.
Remove knock sensor cable clips (4).

Install hint:
Replace cable clips.






Remove vacuum pipe connector from pressure regulator.
Remove fuel injector rail retaining bolts (1) and gently pull fuel injector rail (2) from manifold.
Tightening torque 25 Nm.






Drain fuel rail prior to removing injectors.
Remove fuel injector retaining clip (1) and remove injector (2).






Install hint: Coat O-rings with anti-friction rubber coating (e.g. petroleum jelly).


NOTE: Read out fault memory of EMS2000 control module, check stored fault memory, rectify faults, clear fault memory.