SAAB WIS ONLINE

Injector (206), Z19

Injector (206), Z19

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.


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

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.


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. Unplug the injector connectors.


4. Detach the return fuel hoses.

5. Detach the fuel pipes from the injectors and fuel rail. Use a wrench to counterhold at the injector when removing the pipe.

6. Detach the cables from the crankcase ventilation pipe.

Important

Cars with preheated crankcase ventilation: Be careful not to damage the heating coil in the hose.



7. Detach the crankcase ventilation pipe and raise it slightly.

8. Remove the nuts and washers of the injectors. Remove the injector with holder. If the nozzles cannot be raised by hand, use 32 025 013 Injector removal tool using 83 90 270 Sliding hammer and 32 025 012 Sliding hammer adapter .


Important

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


9. Remove the injectors in the following order:

1-2-3-4

10. Clean the injector sealing surfaces in the cylinder head using 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 holder and new seals in the following order: 4-3-2-1. Fit the washers and nuts.

Tightening torque: 25 Nm (18 lbf ft)


2. Fit the crankcase ventilation pipe.


3. Attach the cables to the crankcase ventilation pipe.

4. Check that the fuel pipe sealing surfaces are clean and undamaged. Fit the pipes with no tension and fit the nuts by hand.

Tightening torque: 25 Nm (18 lbf ft)

5. Attach the return fuel hoses.


6. Plug in the connectors.

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

8. Start the engine and check the fuel system for leaks.

Connect the diagnostic tool and clear any diagnostic trouble codes.

9. Fit the insulation and upper engine cover.