Caution: Do not allow dirt to enter the fuel system tract!
Caution: Remember that injectors are precision equipment and must be handled with extreme care!
1. The procedures for removing the injectors are fundamentally similar for all engines considered in this Manual. Below is a description of the injector removal operations using the Z17DTH engine as an example. The features of other engines are determined only by the layout of other power plant systems.
Z17DTH Engine
Removal
2. Disconnect the cable from the negative terminal of the battery (see Chapter 5).
3. Remove the engine cover (see Chapter 2) and an air cleaner with an intake duct (see Section 6).
4. Remove the air ducts located above the injectors and high-pressure fuel lines and blocking access to them.
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5. Disconnect the 4 injector wiring connectors (see accompanying illustration), unscrew the 2 mounting bolts and, using the KM-717 tool, disconnect the electrical wiring connectors from the 4 glow plugs.
6. Prepare a container for draining the fuel and disconnect the high-pressure fuel lines from the fuel distribution line and from the injectors. Caution: After removing the lines, immediately close the holes in the line and injectors with plugs to prevent contamination from entering the injection system!
7. Separate the oil line (see illustration 17.5) from the injectors and fuel distribution line.
8. Remove the right and left rear lifting eyes and remove the engine oil dipstick tube mounting bracket.
9. Remove the injector caps and their fuel supply lines (see accompanying illustration).
10. Remove 11 bolts and camshaft cover.
11. Unscrew the mounting bolts of the mounting brackets (see accompanying illustration) and remove the injectors from the engine. If, when removing the injectors, any of them are pulled out together with the heat-protective sleeve, replace the sealing rings on the sleeve and install it in place using the KM-6357 device.
Installation
12. Installation is carried out in the reverse order of removal. Do not forget to replace the rubber and copper gaskets of the injectors and the seals of other removed components. Before tightening the injector mounting bolts, align them using a special device (see accompanying illustration). Fuel line caps must be installed with the "UP" marking facing up.
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