Removal and Replacement

Injector/pulse damper, replacement

Note! For model year 2001-, see Injectors/pulsation dampers, replacing, B5234T9, B5244T7 Removal and Replacement.

Note! Since the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Preparation




Depressurize the fuel system according to: Fuel system pressure release Fuel System Pressure Release.
Remove the cover over the fuel rail.
Disconnect the injector connectors.
Blow clean around the injectors.
Remove the mounting screws from the fuel rail
Separate the fuel line quick-release connector.
Spray universal oil or similar around the injector terminals on the intake manifold.
Pull out the fuel rail and injectors. Do not work them loose from side to side.

Note! Handle the injectors carefully to avoid damaging the injectors' fuel nozzles and fuel needles.

Removing injectors and pulsation dampers





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

Installing injectors and pulsation dampers
Lubricate the injector O-rings with lubricant 116 1580.
Install the new injector.

Note! If the fuel nozzle has worked loose from the injector, a new injector must be used.

Installing the pulsation damper
Lubricate the new pulsation damper O-ring with lubricant 116 1580.
Install the new pulsation damper.

Installing the mounting rail
Position the mounting rail. The injectors may need to be pulled away from the fuel rail a few millimeters to install the rail.
Tighten the mounting rail to the fuel rail

Finishing




Press the fuel rail down. Ensure that all injectors locate correctly.
Screw the fuel rail into place. Use new screws . Tighten to 10 Nm .
Press the quick-release connector together until a clicking sound is heard.
At the same time connect all the connectors to the injectors.
Reinstall the cover over the fuel rail.
Start the engine. Check for fuel leakage.