Removal and Replacement

Injectors/pulsation dampers, replacing

Special tools:
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)

Note! As 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




Drain the fuel system. See 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.
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.
Pull out the fuel rail and injectors. Do not work them loose from side to side.

Note! Handle the injectors carefully to avoid damage to the nozzles and 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.

Caution! In instances when the injectors must be replaced; all the injectors must be replaced at the same time (sold in sets). This is to ensure that the emission levels are correct.

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

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.