Removal and installation of jets

Defective jets can cause severe engine knock and can cause bearing failures. In such a case, start the engine at idle and loosen the union nuts of the jet pipes one by one. If after you loosen the union nut the engine stops knocking, you have found a defective jet. Defective jets can be found by unscrewing the union nuts on the jet pipes, while the engine should be idling at high speeds at this time. If the number of revolutions remains the same after you unscrew the union nuts, then the jet is defective. You can also check the jets with a pressure gauge (work is done in the workshop, the specified injection pressure: 150-165 bar).

The first signs of malfunctioning jets are:

• lack of ignition
• engine overheating
• engine power reduction
• thick black exhaust
• high fuel consumption

Withdrawal

Disconnect the ground wire (-) from the battery.

Attention! As a result, data in electronic storage devices, such as an engine fault memory or a radio code, are erased. Please read the section carefully "Removing and installing the battery", before disconnecting it.

Thoroughly clean the outside of the high pressure fuel lines and fuel return lines with cold solvent or diesel fuel.



Completely remove the high pressure fuel lines -1-, to do this, unscrew the union nuts using a wrench, for example HAZET 4550.

Attention! Do not change the shape of the fuel lines. Using suitable plugs, close the jets and the high pressure fuel pump to prevent dirt from getting inside.

If you need to remove the fastening clips of the fuel lines, first mark their installation position with a felt-tip pen.

Carefully remove the drain hoses -3- from the jets. These hoses connect the jets to each other. On the last jet, which is located on the side of the gearbox, a blind cap is installed.

Remove the jets using a removable wrench head SW27, for example HAZET 4555. Close the jets from below with plugs to prevent dirt from getting inside.

Attention! Do not let the jets fall down.

Remove thermal seal -1-.

Installation

In principle, only new thermal seals are used between the cylinder head and the jets. The recess should look up. The arrow points to the cylinder head.


Tighten the jets to 80 Nm.

Tighten the wires of the jets with a torque of 20 Nm.

If removed, then, in accordance with the marks made, install the mounting clips.

Connect the fuel drain lines.

Connect ground wire (-) to the battery. Set the clock and set the radio's anti-theft code.

Start the engine and check the fuel system for leaks.