Removal Procedure
WARNING: This page is about a different variant/trim than selected.
WARNING:
Refer to Diesel/Gasoline Vapors Warning
WARNING:
Refer to Safety Goggles and Fuel Warning
NOTE:
- 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. Store the components so that contaminants cannot enter.
- In order to reuse the injectors, mark the injectors so that they can be installed to the same cylinder.
- Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (KL9)
- Remove Intake Manifold Cover. Refer to Intake Manifold Cover Replacement
- Disconnect Fuel Injector Electrical Connectors (1) (Qty: 4)
- Remove and DISCARD the 4 fuel return hose clamps (1).
- Remove and DISCARD Clamp (2)
- Disconnect Fuel Return Hose (1) @ Diesel Fuel Separator
- Unclip Fuel Return Hose (1) @ Fuel Injector (Qty: 4)
- Remove Fuel Return Hose (1)
- Remove and DISCARD the seals. (3) (Qty: 4)
- Remove Fuel Injector Insulator (1)
- Remove and DISCARD Fuel Injection Fuel Feed Pipes (1) (Qty: 4)
- Close all open connections, using suitable closure plugs.
- Remove and DISCARD Fuel Injector Bracket Bolts (1) (Qty: 4)
- Remove Fuel Injector Brackets (2) (Qty: 4)
- Pull out the 4 fuel injectors (2) with the EN-51187 remover (3) along with the EN-51146-1-3 sliding hammer (1).
- Remove Fuel Injectors (1) (Qty: 4)
- Remove and DISCARD Fuel Injector Washers (2) (Qty: 4)
- Protect the 4 fuel injector nozzles with suitable caps.
NOTE:
If the injector can not be removed by hand, use the EN-51187 remover and remove the injector by turning at the hexagon.