REMOVAL AND INSTALLATION


RECOMMENDED TOOLS
[12] Pipe spanner (-).4220-T.C
[22] Extension (-).1603-E
[23] Torque wrench 4220-T.B/ 4220-T.A
[24] Socket for allen screws (-).1608-D
[25] Torque wrench (-).1608-A
[26] Adaptor for tightening diesel injector (-).1608-C
[27] T-extension (-).1603-E (K1608 kit)
[38] Diesel injector end-piece 1616.ZZ-F2
[39] Plugs 1616.ZZ-E
[40] Diesel injector extractor support 1616.ZZ-F1
[41] Diesel injector extractor support 1616.ZZ-F3
[42] Diesel injector extractor rail 1616.ZZ-B

REMOVAL SERVICE POINTS

Unscrew:
1.The 5 unions (53); Using tools [12] and [22].
2.The 4 unions (51); Using tools [12] and [22].
3.Remove: The 4 high-pressure fuel supply pipes (52):
4.The bolts (54).
5.The clamps (56).
caution Recover the support pins (59)
6.Remove the injectors (57).
7.Remove the bolts (58).
8.Remove the fuel high-pressure common injection rail (55).
note If it is difficult to remove the injectors, use the following procedure.

9.Remove the tube (60).
10.Fits the blanking piece [39] onto the diesel injector.
11.Screw the tool [38] onto the diesel injector.

12.Install the tool [40] (On the timing side, in contact with the cylinder head cover).
13.Install the tool [41] (On the gearbox side, in contact with the camshaft main bearing cap casting).

14.Fix the tool [42] on the tools [40] and [41].
15.Fit the bolt "d" of tool [38] through the slot in tool [42].
16.Tighten the bolt "d" of tool [38] until the diesel injector is extracted.
note If it is impossible to remove the diesel injector. Attempt the extraction using the extractor: CTIA 0413 or PICHLER 60383305 (Replacement Parts reference; See workshop equipment). It is imperative that the manufacturers’ manuals are used.

17.Exert a counter-torque at "e".
18.Loosen the union (64).
19.Remove vacuum pump (61).
20.Remove the high-pressure fuel pump (62) with the fuel entry pipe.
21.Remove the high-pressure fuel pipe (63).
22.Remove the bolt (66).
23.Remove the bracket (65).
24.Remove the coolant outlet housing (67)

INSTALLATION SERVICE POINTS



1.Install a new seal on the coolant outlet housing (89).
Install
2.Tighten the coolant outlet housing (89) to torque of 8 ± 1 N·m.
3.Install the clamp (87).
4.Tighten the bolt (88) to torque of 8 ± 1 N·m.
5.Install the high-pressure fuel pipe (85) (new)
6.Install the high-pressure fuel pump (84) with the entry pipe.
7.Install the vacuum pump (83).
8.Tighten the fixings of the high-pressure fuel pump (84) to torque 22 ± 2 N·m.

9.Preparing a diesel injector:
10.Install the centring ring (91) on the diesel injector (90).
11.Install the new copper seal (92) on the diesel injector (90).



caution Refit the diesel injectors observing the marks made on removal (if the injectors are to be reused)
1.Reposer:
2.The diesel injectors (90).
3.The clamp (99) thrust pins (97).
4.The clamps (99).
5.The fuel high-pressure common injection rail (93).
6.The screws (95), without tightening them.
7.The high-pressure fuel pipes (98).
caution The refitting of the 4 high-pressure fuel pipes (98) and the tightening of the unions (96), (94) by hand to the end of the thread positions the diesel injectors.
8.Tighten by hand to the end of the thread:
9.The 4 high-pressure fuel pipe (98) unions (96) on the diesel injectors (90).
10.The 5 unions (94) of the high-pressure fuel pipes (98) and (85) on the high-pressure fuel injection common rail (93).
11.Pre-tighten the bolts to (100) 5 ± 1 N·m; By means of tools [24], [25].

12.Respect the following method of angular tightening:
13.Position the identifying zero “af” of the tool [26] facing the operator.
14.Move the mobile index "ag" of the tool [26] and position it to face the gradation 130°.
15.Gradually tighten the bolt, in a single operation, bringing back the detachable index "ag" opposite the identifying zero "af" of the tool [26].
16.Angle tighten the 4 bolts (100) to 130 ± 5°; By means of tools [24], [26], [27].

17.Tighten the unions (96) on the diesel injectors; By means of tools [12], [22], [23].
18.Tighten the unions (96) to temporary to torque of 22 ± 2 N·m.
19.Tighten the unions (96) to torque of 25 ± 2 N·m.

20.Tighten the 4 unions (94) of the fuel supply pipes (98) of the fuel injectors on the high-pressure fuel injection common rail; By means of tools [12], [22], [23].
21.Tighten the unions (94) to temporary to torque of 22 ± 2 N·m.
22.Tighten the unions (94) to torque of 25 ± 2 N·m.

caution The following operations require the intervention of a second person to support the high-pressure fuel supply pipe (85); Using an 5.4 mm shim (During the union tightening method)
23.Position a 5.4 mm shim between the new high-pressure fuel supply pipe (85) and the engine lifting eye (At "ah").

24.Method for tightening the union (86):
25.Apply a counter-torque (At "aj").
26.Pre-tightening of the high-pressure fuel supply pipe (85) onto the high-pressure fuel pump to 22 ± 2 N·m; Using the tools [12], [22], [23].
27.Tighten to 25 ± 2 N·m; Using the tools [12], [22], [23].

28.Method for tightening the union (94); Using the tools [12], [22], [23]:
29.Pre-tightening to 22 ± 2 N·m.
30.Tighten to 25 ± 2 N·m.




1.A: Correct fitting.
2.B: Incorrect fitting.
caution The retention bracket of the high-pressure pipe (85) must be free to rotate on the high-pressure fuel supply pipe; The retaining clip must not be closed.


1.Fit: The retaining clip fixing bolt (101).
2.Tighten:
3.The bolt fixing the retention bracket to 8 ± 2 N·m.
4.The fixing bolts of the high-pressure fuel injection common rail to 18 ± 2 N·m.