Fuel Injection Nozzle / Fan Motor / Pressure Equalizer, Replacing
Fuel injection nozzle / fan motor / pressure equalizer, replacing
The information below applies to cars manufactured up to week 38 2001 inclusive.
Information for cars manufactured from week 39 2001 inclusive. See Fuel injection nozzle / fan motor / pressure equalizer, replacing Fuel Injection Nozzle / Fan Motor / Pressure Equalizer, Replacing
Removal
Preparations
Remove the heater. See Engine coolant heater, replacing Engine Coolant Heater, Replacing.
Fan shroud
Release the fan shroud from the mounting: Slacken off the 3 screws.
Lift off the fan shroud.
Fan and combustion chamber
Remove the glow plugs. See Glow plugs, engine coolant heater, replacing Glow Plugs, Engine Coolant Heater, Replacing.
Cut the tie strap.
Separate the connectors for the fan motor.
Remove the flame sensor from the rubber bushing on the mounting.
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 edge / threadandthe nozzle unit. A damaged nozzle unit can result in imbalance (combustion noise) and disruption of 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.
Note! Note the markings on the engine mounting and the heat exchanger, directly above the glow plug (these indicate the positioning).
Combustion chamber
Release the combustion chamber: Slacken off the 3 screws from the mounting.
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 of screws. This could damage the fan wheel.
- atomizer
- the spacer
- outer nozzle head
- fuel injection nozzle.
Note! Do not forget the spacers and washers; one spacer for diesel, one spacer and two washers for gasoline (1).
Blower fan motor and motor mounting
Remove the 3 screws between the motor mounting and the mounting.
Slacken off the mounting with the fuel line.
Remove the motor mounting.
Note! Note the motor holder position in relation to the fan motor. It is vital that the motor 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 with the fuel line.
Installation
New 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:
- the motor holder on a new motor
- the motor on the motor mounting.
Tighten to 2 Nm.
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 and washer
Note! Gasoline and diesel versions have different fuel injection nozzles.
- outer nozzle head (with washer against the gasoline fuel injection nozzle)
- conical spacer with the cone pointing towards the outer nozzle head
- atomizer.
on the screw.
Then install the screw and components onto the fan motor spindle. Tighten to 2 Nm.
Install the combustion chamber.
Note! The glow plug socket must be to the left of the lead-in for the fan motor wiring.
Wires
Install the tie strap.
Connect the wiring 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 (3 screws).
Heat exchanger and glow plug
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.
Install:
- the glow plug in the heat exchanger.
Note! If the glow plug can be screwed in by hand the glow plug socket in the flame shield has been centered correctly. Tighten to 15 Nm.
- the protective sleeve on the glow plug.
The fuel line quick-release connector
Install:
- the quick-release connector on the fuel line
- the connector.
The heater
Note! Always check that there is clearance between the fuel line and water hose.
Reinstall the heater. See Engine coolant heater, replacing Engine Coolant Heater, Replacing.
Reinstall the wind deflector. See Wind deflector, replacement Service and Repair
Final check
Note! Start the engine and let it idle for a few seconds before starting the heater.
Test run the heater. Check the function of the heater. See Engine coolant heater, test running Engine Coolant Heater, Test Running
Check both the coolant hoses and the fuel lines for leakage.
Top up the coolant if necessary.
Check that no diagnostic trouble codes (DTC) have been stored during the repair work.