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Injector (206), Z19DTH

Injector (206), Z19DTH

To remove

Warning

The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Important

Be very thorough in terms of cleanliness when working in the fuel system. Malfunctions can also occur due to very small dirt particles. Prevent dirt from entering the fuel system by cleaning the hoses and plugging the pipes and lines upon removal using 93 161 370 Plug set. Store the components so that contaminants cannot enter.


Warning

Diesel under high pressure! So wait for at least one minute after switching off the engine before starting work in the fuel system. Diesel fumes are explosive and can cause severe burn injuries.


Important

If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.



1. Open the bonnet.

2. Remove the upper engine cover and insulation.

3. Remove the connectors from the injectors.


4. Remove the fuel return hoses.

5. Remove the fuel pipes from the injectors and fuel rail. Hold the injector with a spanner when detaching the pipe.

6. Undo the cables from the crankcase ventilation pipe.

7. Undo the crankcase ventilation pipe.

8. Undo the injector with holder. If the nozzles cannot be lifted by hand, use removal tool: 32 025 013 Injector removal tool and 83 90 270 Sliding hammer and 32 025 012 Sliding hammer adapter .


9. Remove the injectors in the following order:

1-2-3-4

Important

If the injectors are to be refitted, mark the injectors so that they can be refitted to the same cylinder.


10. Clean the injector sealing surfaces in the cylinder head. Use 32 025 010 Cleaning tool.



To fit

Important

If new injectors are to be fitted, read and make a note of its classification code. The code is to be used when programming using the diagnostic tool.




1. Fit the injectors with new seals in the following order: 4-3-2-1.

Tightening torque 25 Nm (18 lbf ft).

2. Fit the crankcase ventilation pipe.


3. Fit the cables to the crankcase ventilation pipe.

4. Check that the fuel pipe sealing surfaces are not damaged and are clean. Fit the pipes without strain and mount the nuts by hand.

Tightening torque 25 Nm (18 lbf ft).

5. Fit the fuel return hoses.

6. Fit the connectors.

7. If new injectors are fitted : Connect the diagnostic tool for programming. Select Menu - Engine - Engine management system - Adjustment - Injector Replaced.

8. Start the engine and check that the fuel system is not leaking.

Connect the diagnostic tool and erase any diagnostic trouble codes.

9. Fit the insulation and the upper engine cover.