Special Tools Required
- 00 1 440
- 13 0 161
- 13 0 162
- 13 0 191
- 13 0 192
- 13 0 193
- 13 0 194
- 13 0 195
See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .
See FUEL SYSTEM - SPECIAL TOOLS .
Electric fuel pump starts up automatically when door is opened!
Observe warning on cylinder head cover.
Disconnect battery negative terminal (risk of fire due to short-circuiting on removal). See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .
Carry out installation work on fuel system only with coolant temperature below 40°C.
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high velocity from the fuel injectors!
To reduce the fuel pressure, place rag over fuel injector and carefully tap against the fuel injector with a spanner.
There is a risk of injury if the fuel pressure is not reduced!
Introduced contaminants can cause malfunctions in the system!
- Do not allow any dirt particles or foreign bodies to get into the system.
- Remove all traces of dirt before removing pipes or individual components.
- Use only fluff-free cloths.
- Seal all fuel system openings with protective caps or plugs.
- High-pressure lines may be rescrewed a maximum of 10 times.
Injectors are not waterproof!
Carry out engine cleaning/washing only with ignition coil cover fitted.
Necessary preliminary tasks:
- Remove ignition coils . See 12 13 511 REPLACING IGNITION COILS (N63) .
- Ignition coils must not be fouled by fuel!
The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots!
- Before installing ignition coils, clean spark plug slots with compressed air.
- Make sure the spark plug slot is absolutely clean.
- Remove pressure lines on injectors.
Release bolt (1) and remove holding-down element (2).
Remove injector (1).
Procedure in event of stuck injectors:
Mount special tool 13 0 301 or 13 0 302 (from set of special tools 13 0 300) on the stuck injector. In so doing, attach the special tool at the bottom to the injector and secure at the top with the knurled screw to the injector feed.
Mount special tool 13 0 300 over the stuck injector with special tool 13 0 301 or 13 0 302. In so doing, insert screws (1) in the designated holes and screw down. Tightening torque 13 53 10AZ .
Twist bolt (1) through special tool 13 0 300 into special tool 13 0 301 or 13 0 302 on the stuck injector. Tighten down bolt (1) until the injector is pulled out.
After removing, fit protective caps (1 and 3) to injector tip and fuel line connection.
Installation note: When installing a new injector: Use a new uncoupling element (2). Remove protective cap (1) from injector tip max. 10 min. before installation (Teflon ring swells up)
Installation note: When reusing fuel injector: Replace decoupling element (2). Replace Teflon ring (1). A Teflon ring which has been heated once by engine operation must be replaced before the injector is reinstalled.
Replace Teflon ring: Before replacing the Teflon ring (1), make sure your hands and the work surface are clean and free of oil. Avoid mechanical contact with injector tip (2).
Remove Teflon ring (1) with special tool 13 0 191 from injector (2). Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other tools/agents). Do not clean injector tip.
Push new Teflon ring (1) onto the installation cone 13 0 195.
Push Teflon ring (1) with fingers assisted by the installation cone 13 0 195 onto the injector (2).
To bring the expanded Teflon ring to its installation dimension, slide three assembly sleeves with decreasing diameters onto the injector. Slide assembly sleeve (1) with large opening first onto injector (1). Do not use any lubricating agents.
First slide assembly sleeve 13 0 192 (large diameter) onto injector (1). Then slide assembly sleeve 13 0 193 (medium diameter) onto injector (1).
Finally, press injector (1) into assembly sleeve 13 0 194 (small diameter).
Installation note: Install injector within 10 minutes or slide on protective cap (Fig. 13 14 05) Teflon ring swells up.
Installing injector: Installation of injector is described separately from removal.
Before installing injector in engines that have been run:
- Check injector bore for dirt. Clean only dirty injector bores. Important - do not damage injector!
- Clean injector bore: To do so, preferably slide injector without decoupling element (2) but with new Teflon ring (1) in and out of injector bore several times. The Teflon ring must subsequently be replaced.
- Clean contact surfaces of uncoupling elements (2) in cylinder head.
- Replace decoupling element (2).
Important! Injection quantity compensation!
An injector quantity compensation must be carried out if an injector is replaced or changed on the cylinder side. Injector quantity compensation is carried out with the aid of a so-called adjustment value. The adjustment value is printed in two blocks of three digits on the injector. The adjustment value must be read off before installation!
Enter the adjustment value according to the installation location (cylinder) of the injector. If injector quantity compensation is not carried out, the engine may run roughly or fail to start. Description of injector quantity compensation at end of instructions.
Installing injector: Installation note: Install hold-down device (1) with curvature facing upwards.