The first signs of a bad injector are:
- Drop in engine power;
- Excessively black exhaust gases;
- Thick blue smoke on cold start
- High fuel consumption;
- Engine overheating;
- Knocking in one or more cylinders;
- incomplete combustion.
Withdrawal
1. Remove the inlet pipeline, refer to Section Removal and installation of the inlet pipeline.
2. Clean the high pressure fuel lines with a cold cleaner.
3. Remove the high pressure fuel lines. To do this, use a wrench, for example, HAZET 4550, to unscrew the union nuts at the injectors and injection pump.
4. Cover the openings with protective caps or tape with rubber bands to prevent dirt from getting into them.
5. Disconnect the cable going to the fourth cylinder injector.
6. Disconnect the drain hoses between the nozzles using pliers.
7. Disconnect the injector clamps -2- and remove the injectors.
If the nozzle cannot be removed, you can use an impact puller. To use it, it is necessary to make a special tool that is screwed onto the nozzle.
This tool can be made as follows. Cut off the old nozzle about 5 cm behind the union nut. Braze an M6 nut to the cut end of the pipe.
8. Screw the tool onto the nozzle and attach the impact tool to the brazed nut. Pull out the nozzle.
9. Remove the heat shield.
Installation
10. Be sure to install a new heat shield between the cylinder head and injector.
11. Insert the nozzle.
The nozzle with a needle movement sensor is always inserted into the fourth, that is, into the rear cylinder. You can recognize it by the attached cable.
12. Connect the fourth nozzle cable.
13. Install the clamping collars on the injectors. Tighten the clamp nuts to 10 Nm.
14. Put new drain hoses between the nozzles.
15. Fasten the high pressure fuel lines to the injectors and injection pump with a torque of 25 Nm.
16. Install the inlet pipeline, refer to Section Removal and installation of the inlet pipeline.