Caution! Protect the generator from contamination.
After disconnecting the pressure pipes, it is necessary to seal the holes of the injectors and pipes with special caps.
If one of the sealing elements of the drain pipe for one group of cylinders is damaged, replace the entire pipe assembly.
Injection system device type "Commom-Rail" shown in Fig. 6.119. The replacement of the injection system injectors must be carried out in the following order. Prepare the tools "13.5.020", "13.5.231", "13.5.232" and "13.5.250" and materials for collecting leaking fuel with its subsequent disposal. Protect the generator from contamination. It is imperative to plug the disconnected pipes and injectors with caps. Read information from the fault memory of the ECU of the "DDE" system and turn off the ignition. Remove the intake manifold.
Loosen the union nuts (1, Fig. 6.120) fastening the pressure pipes (2) using the device "13.5.020" on the injector (4) and only loosen the nut on the hydraulic accumulator. Unscrew the nuts (3) fastening the injector and remove the injectors (4) from the cylinder head.
If it is not possible to remove the injector, it is necessary to assemble the tools "13.5.250", "13.5.231" and "13.5.232" and install it on the injector connecting element. Remove (knock out) the injector using the impact weight of the "13.5.250" device.
Check for the presence of the sealing ring (1, Fig. 6.121) on the removed injector. If it is not there, then remove the ring from the cylinder head.
The injectors should be installed in the reverse order, and it is necessary to: Clean the injector channels. Replace the sealing ring (1) on the injector (2) and the sealing ring of the injector body. Pay attention to the correct position of the flange (3). Tighten the nuts (M6) securing the injectors to a torque of 9.0 N·m (0.9 kgf·m).
Installation of pressure pipelines must be carried out in the following order:
- tighten all union nuts of pressure pipes by hand;
- tighten the union nuts on the injectors to a torque of 23 N·m (2.3 kgf·m):
- tighten the union nuts on the hydraulic accumulator and high-pressure fuel pump to a torque of 23 N·m (2.3 kgf·m)
- perform a test drive with high engine speed. Visually check the tightness of all connections of the injection system units.
Attention! Correction of new injectors is necessary to ensure their full functionality. In case of replacement of more than two injectors, it is necessary to perform "Correction of injector characteristics field" according to DIS-tester documentation.
When installing new injectors of the "EU3" type, you need to count the first six digits/letters accordingly (sector, Fig. 6.122). Enter numbers and letters in accordance with the installation location (cylinders) of the new injectors into the software and perform the correction of the characteristics field.
When installing new injectors of the "EU4" type, you need to count the first seven digits and letters accordingly (sector, Fig. 6123). Enter numbers and letters in accordance with the installation location (cylinders) of the new injectors into the software and perform the correction of the characteristics field.
Upon completion of the work on replacing the injectors, it is necessary to read the information from the fault memory of the ECU of the "DDE" system. If they are detected, take measures to eliminate them and erase the information from the fault memory of the ECU. Check the functioning of the "DDE" system.
[The article was copied from an online resource BMWMAN.RU]