Special tool
 | Worldwide Diagnostic System (WDS) 418-F224 |
General equipment: Pneumatic vacuum gun.
| Name | Specification |
| Grease for nipple connection of high pressure fuel supply line TBD | TBD |
Removal
All cars
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow fuel handling precautions. Failure to follow these instructions may result in personal injury.
WARNING: Do not carry out any repairs to the fuel injection system while the engine is running. Fuel pressure in the system can reach 1600 bar. Failure to follow these instructions may result in injury.
WARNING: Do not perform any repairs to the fuel injection system without verifying that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or below 30°C, whichever is greater. Failure to follow these instructions may result in personal injury.
WARNING: After stopping the engine, wait at least one minute before attempting any repairs to the fuel injection system. Failure to follow these instructions may result in injury.
CAUTION: Make sure that the service area where the vehicle is being worked on is as clean and dust-free as possible. Foreign matter from clutch, brake, machining or welding operations may contaminate the fuel system and cause subsequent malfunction.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Diesel injection equipment is manufactured to very precise tolerances and with very small clearances. It is therefore especially important to maintain absolute cleanliness when working with these components. Open holes or lines should always be plugged using suitable plugs.
CAUTION: Do not disassemble the fuel injectors or clean their nozzles, even using ultrasonic cleaning. Always install new fuel injectors when necessary.
1. Using the Datalogger function of the Worldwide Diagnostic System (WDS), check that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or a temperature below 30°C, whichever is greater.
2. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.
3. Remove the top engine cover.
4. Remove the air deflector.
5. Disconnect the charge air cooler inlet pipe.
Cars with diesel engine 100 hp.
6. Disconnect the charge air cooler outlet pipe. Disconnect the vacuum line from the charge air cooler outlet pipe.
Cars with 115 hp diesel engine.
7. Disconnect the charge air cooler outlet pipe.
All cars
8. Disconnect the intake air temperature (IAT) sensor connector and remove the charge air cooler and lines.
9. Disconnect the fuel pressure sensor connector and cover the connector with a lint-free cloth to prevent it from becoming contaminated with cleaning fluid.
10.
CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.
Cover the generator with a lint-free material to prevent contamination.
11.
CAUTION: Cover the fuel injector connectors with a lint-free material to prevent contamination from cleaning fluid.
Clean the fuel injectors, fuel rail, high-pressure fuel supply lines and adjacent areas. For more information, refer to the Cleaning the Fuel Injection System Components chapter in this section.
12. Remove the high pressure fuel supply line bracket.
13. Clean the fuel pump, fuel rail, high pressure fuel supply line and surrounding areas. For more information, refer to the Cleaning the Fuel Injection System Components chapter in this section.
14.
CAUTION: The high pressure fuel supply line must remain in contact with the fuel pump and fuel rail until all connections have been disconnected and cleaned. Failure to follow this instruction may allow dirt to enter the fuel injection system.
Disconnect the high pressure fuel supply line and clamp from the fuel pump and fuel rail.
15.
CAUTION: The high pressure fuel supply line must remain in contact with the fuel pump and fuel rail until all connections have been disconnected and cleaned. Failure to follow this instruction may allow dirt to enter the fuel injection system.
Using an air vacuum gun, remove foreign material from the high pressure fuel supply line, fuel pump and fuel rail.
16. Remove the high pressure fuel supply line and discard it as no longer needed.
17. Using an air vacuum gun, remove foreign material from the fuel pump and fuel rail.
18. Install plugs into the open threaded holes on the fuel pump and fuel rail.
19.
NOTE: Mark the orientation of the clamp to ensure it is installed in the exact same position.
Remove the clamp from the high pressure fuel supply line.
20. Discard the high pressure fuel supply line as it is no longer needed.
21.
NOTE: Mark the orientation of the clamps to ensure they are installed in exactly the same position.
Remove the high pressure fuel supply line clamps.
22.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel injectors until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Disconnect the high pressure fuel supply lines from the fuel injectors (PCV hoses shown removed for clarity).
23.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel rail until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Disconnect the high pressure fuel supply lines.
24.
CAUTION: The high pressure fuel supply lines must remain in contact with the fuel injectors until all connections have been disconnected and cleaned. Failure to follow this instruction may result in dirt entering the fuel injection system.
Using an air vacuum gun, remove foreign material from the high pressure fuel supply lines and fuel rail.
25. Remove the high pressure fuel supply lines and discard them as no longer needed.
26. Using an air vacuum gun, remove foreign material from the fuel injectors and fuel rail.
27. Install plugs into the open threaded holes of the fuel injectors and fuel manifold.
28. Remove the fuel manifold.
Installation
All cars
WARNING: Do not smoke or allow a lighted cigarette or open flame of any type when working with or near fuel-related items. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.
CAUTION: Make sure that the service area where the vehicle is being worked on is as clean and dust-free as possible. Foreign matter from clutch, brake, machining or welding operations may contaminate the fuel system and cause subsequent malfunction.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Diesel injection equipment is manufactured to very precise tolerances and with very small clearances. It is therefore especially important to maintain absolute cleanliness when working with these components. Open holes or lines should always be plugged using suitable plugs.
CAUTION: Do not disassemble the fuel injectors or clean their nozzles, even using ultrasonic cleaning. Always install new fuel injectors when necessary.
NOTE: Install new high pressure fuel supply lines.
1.
NOTE: Do not tighten the fuel rail mounting bolts at this stage.
Install the fuel manifold.
2. Lubricate the threads of the high pressure fuel supply line nipple connections using clean grease.
3.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to do so may result in damage to the ends of the fuel line and foreign material being introduced into the fuel injection system.
CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.
NOTE: To facilitate identification of the high pressure fuel supply lines, the connections on the fuel injector side are engraved with the cylinder number.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the fuel line nipple in contact with the fuel rail cone when connecting.
Connect new high pressure fuel supply lines to the fuel rail. Discard plugs as they are no longer needed.
4.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to do so may result in damage to the ends of the fuel line and foreign material being introduced into the fuel injection system.
CAUTION: Remove the plugs from the fuel supply line, fuel injectors and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the fuel line nipple in contact with the fuel injector cone when connecting.
Connect the high pressure fuel supply lines to the fuel injectors. Discard the plugs as they are no longer needed.
5.
NOTE: Ensure that the clamp is installed in the same position as it was before removal.
Install the high pressure fuel supply line clamp to the high pressure fuel supply line.
6. Lubricate the threads of the high pressure fuel supply line nipple connections using clean grease.
7.
CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.
Cover the generator with a lint-free material to prevent contamination.
8.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to do so may result in damage to the ends of the fuel line and foreign material being introduced into the fuel injection system.
CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel pump and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the fuel line nipples in contact with the fuel pump and fuel rail cones when connecting.
Install a new high pressure fuel supply line.
- 1. Connect the high pressure fuel supply line to the fuel rail.
- 2. Connect the high pressure fuel supply line to the fuel pump.
- Discard the plugs as they are no longer needed.
9. Tighten the fuel rail mounting bolts.
10.
NOTE: Do not tighten the high pressure fuel supply line clamps at this stage.
NOTE: The clamps must be installed in exactly the same position from which they were removed.
Install the high pressure fuel supply line clamps.
11.
CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.
Tighten the fuel feed line nipples at the fuel injectors (PCV hose shown removed for clarity).
12.
CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.
Tighten the fuel supply line nipple connections to the fuel rail.
13.
CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.
Tighten the nipple connections of the high-pressure fuel supply lines.
- 1. Tighten the nipple connections of the high pressure fuel supply lines to the fuel rail.
- 2. Tighten the nipple connection of the high pressure fuel supply line to the fuel pump.
14. Install the high pressure fuel supply line bracket.
15.
NOTE: The clamps must be installed in exactly the same position from which they were removed.
Tighten the high pressure fuel supply line clamps.
16. Connect the fuel pressure sensor connector.
17. Remove the lint-free material from the generator.
18. Install the charge air cooler and lines and connect the IAT sensor plug.
Cars with 115 hp diesel engine.
19.
CAUTION: Make sure the inside of the end of the charge air cooler outlet pipe is clean and free of oil, as this will reduce adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the charge air cooler outlet pipe.
Cars with diesel engine 100 hp.
20.
CAUTION: Make sure the inside of the charge air cooler outlet pipe end is clean and free of oil, as this will reduce adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the outlet pipe to the charge air cooler. Connect the vacuum line to the outlet pipe of the charge air cooler.
All cars
21.
CAUTION: Make sure that the inside of the charge air cooler intake pipe is clean and free of oil, as this will impair the bond between the pipe and the charge air cooler. Failure to follow this instruction may result in engine damage.
Connect the charge air cooler inlet pipe.
22. Install the air deflector.
23. Install the top engine cover.
24. Connect the ground cable to the battery. For additional information, refer to Section 414-01.
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