Special tool
 Fuel injector removal tool 303-1127 |
Removing
WARNING: Do not smoke or walk with a lit cigarette or open flame of any type while working on or near fuel related items. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.
WARNING: Before attempting any repair to the high pressure fuel injection system, wait at least 30 seconds after stopping the engine Failure to follow this instruction could result in personal injury.
CAUTION: This procedure is related to fuel handling. Always be aware of the possibility of fuel splashing and observe fuel safety precautions. Failure to follow these instructions may result in injury.
CAUTION: Do not make any repairs to the fuel injection system while the engine is running. Fuel pressure in the system can reach 1650 bar (23.931 psi inch). Failure to follow this instruction may result in injury.
WARNING: Make sure that the workshop area where the vehicle is being worked on is thoroughly cleaned and free from dust. Dirt and dust from clutch, brake, or machining or welding operations can contaminate the fuel system and result in improper operation.
CAUTION: Do not disconnect the fuel injector electrical connectors while the engine is running. Failure to do so may result in serious engine damage.
CAUTION: Always perform the cleaning procedure before making any repairs to the fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
WARNING: Diesel fuel injection equipment is manufactured to very precise tolerances and with very close clearances. Therefore, when working with these elements, it is especially important to observe absolute cleanliness. Open holes or lines should always be plugged with appropriate plugs. Failure to follow this instruction may result in dirt entering the fuel injection system.
WARNING: Do not disassemble fuel injectors or clean their nozzles, even with ultrasonication. Always install new fuel injectors if necessary.
1. Disconnect the wire "masses" from the battery. For more information refer to Specification.
2. Remove the engine cover. For more information refer to Engine Cover - 2.7L Diesel (12.30.50)
3. Disconnect the low pressure fuel lines. Plug open connections.
4. Disconnect both hoses from the EGR coolant overflow pipe. Clamp the EGR bypass pipe to minimize coolant loss.
5. Remove the EGR coolant overflow pipe. Turn out 2 bolts.
6. Remove the battery. For more information refer to Battery (86.15.01)
7.
NOTE: Right hand drive vehicle shown, reverse order on left hand drive vehicle.
Disconnect the 3 electrical connectors of the engine wiring harness in the order shown.
8. Release the engine wiring harness from the bulkhead.
9. Remove a noise isolation of fuel atomizers.
10. Disunite electric sockets of fuel atomizers.
11. Release the engine wiring harness. Release 4 clips.
12.
CAUTION: Ensure that the high pressure fuel supply line remains in contact with the fuel injector and fuel manifold until both pin connections are disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Make sure that the fuel injector adapter fitting does not move when the high pressure fuel supply line is released. Failure to do so may result in failure of the fuel injector or fuel injector adapter fitting.
Remove the high pressure fuel supply line and discard it.
- Loosen the fastening of the high pressure fuel supply line from the fuel injector and fuel manifold.
- Plug open connections.
13. Disconnect the fuel return line from the fuel injector. Remove the fuel return line clamp.
14. Turn away 2 bolts of fastening of a fuel atomizer. Remove the fuel injector clamp spacer.
15. Install the special tool studs.
16.
CAUTION: Make sure the legs of the puller are correctly engaged with the fuel injector. Failure to do so may result in damage to the part.
Install the legs of the special tool on the studs.
17. Remove the fuel injector.
- Install the special tool stop plate on the special tool legs (puller).
- Rotate the special tool bolts clockwise evenly.
- Remove the special tool.
- Remove and discard the fuel injector clamp.
- Remove and discard the sealing washer.
Installation
1.
WARNING: Do not disassemble fuel injectors or clean their nozzles, even with ultrasonication. Always install new fuel injectors if necessary.
CAUTION: Do not use tools to install a new fuel return line mounting clip. Failure to do so may result in damage to the mounting clip.
Install a new fuel injector clip.
- 1. Install the fuel injector clamp spacer.
- 2. Install a new fuel return pipe clamp.
- 3. Install a new sealing washer.
2. Install the fuel injector. Insert and tighten 2 bolts (tightening torque 10 Nm).
3.
CAUTION: Make sure the fuel return line clamp is correctly installed on the fuel injector before installing the fuel return line.
Connect the fuel return line to the fuel injector.
- Visually inspect the fuel return line O-rings for damage.
- Apply a thin coat of petroleum jelly to the O-rings on the fuel return line.
CAUTION: Do not strike the high pressure fuel line seals as this may damage the ends of the line and allow dirt to enter the fuel injection system.
CAUTION: When tightening the nipple connections, apply pressure to the high pressure fuel supply line to keep the sealing lenses in contact with the fuel injector and fuel rail cones.
Install a new high pressure fuel line.
- Remove plugs from open connections.
- Step 1: Tighten the high pressure fuel line fitting on the injector side (tightening torque 15 Nm).
- Step 2: Tighten the high pressure fuel line fitting at the fuel rail side (tightening torque 15 Nm).
- Step 1: Tighten the high pressure fuel line fitting on the injector side (tightening torque 30 Nm).
- Step 2: Tighten the high pressure fuel line fitting at the fuel rail side (tightening torque 30 Nm).
6. Connect the fuel injector electrical connectors.
7. Establish a noise isolation of fuel atomizers.
8. Attach the engine wiring harness to the bulkhead.
9. Connect the 3 electrical connectors of the wiring harness.
10. Install the battery. For more information refer to Battery (86.15.01)
11. Install the EGR coolant overflow pipe.
- Screw in the 2 remaining bolts.
- Tighten (tightening torque 13 Nm).
13. Connect the low pressure fuel lines. Remove plugs from open connections.
14. Install the engine cover. For more information refer to Engine Cover - 2.7L Diesel (12.30.50)
15. Connect the wire "masses" to the battery. For more information refer to Specification.
16. Check the coolant level, top up if necessary.
17. Remove air from the fuel system.
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