13 53 315 Removing and installing/replacing all injectors in injection system (N57 D30O 1)

Special tools required:

IMPORTANT: When working on the oil, coolant or fuel circuit, you must protect the alternator against contamination.
Cover alternator with suitable materials.

Use only fluff-free cloths
Remove all traces of dirt contamination before dismantling lines or separate components

Recycling:

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

Read out the fault memory of the DDE control unit.
Switch off ignition.
DETACH leakage oil lines from the injectors.
Remove ALL PRESSURE LINES to injectors.
Seal all fuel system openings with protective caps.

Release screw (1) of clamping claw.

Remove clamping claw, screw and centering ring.

Pull out injector with light rotational movements.

Copper sealing ring must be replaced after clamping jaw is released.

Installation note:

Retighten clamping claw rest (cylinder head cover mounting).

Tightening torque 13 53 5AZ .

Fig 1: Identifying Injection System Screws

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During assembly, make sure washer is correctly positioned in relation to screw centering in order to align clamping claw. Secure clamping claw in installation position to jointing torque.

Tightening torque 13 53 1AZ .

Cleaning injector slots:

Copper sealing ring must not remain in injector slot.

Place sealing cap 13 5 215 with mounting rod 13 5 214 into injector slot. Remove fitting rod.

Fig 2: Placing Sealing Cap (13 5 215)

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Place the cleaning tool with brush head 13 5 210 into injector slot.

Fig 3: Identifying Brush Head (13 5 210)

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Using a suitable tool (SW8) move brush head up and down in the injector slot in rotating movements. After removing the cleaning tool, blow out the injector slot with compressed air.

IMPORTANT: Wear safety goggles and cover injector slot with cleaning cloth or similar.

Remove seal plugs 13 5 215 again with mounting rod 13 5 214 .

Fig 4: Moving Brush Head

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NOTE: Replace copper sealing ring (1) on injector (2) without fail.

Installation note:

Lightly lubricate injectors with highly heat-resistant grease before installing in injector slot (above copper sealing ring up to injector slot end (refer to CONSUMABLES 4.5 ).

Observe installation position of high-pressure connection.

Fig 5: Identifying Copper Sealing Ring And Injector

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The adjustment values must be read off in each case when new injectors are installed.

The adjustment value (7-position letter/number code) is engraved on each injector.

The digits/letters correspond to the installation location (cylinder) of the new injectors.

Select "DDE".
Select "Adjustment, injection quantity compensation"
Select "Test schedule"
The adjustment must be entered for each cylinder on which an injector has been replaced.

Fig 6: Identifying Injection System Adjustment Value
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It is necessary to adjust the new injectors to ensure their full operability.

NOTE: Assemble engine.
Check stored fault messages.
Delete fault memory
Check fuel system for tightness.