Removal and installation of the pump nozzle

The sequence of removal and installation of unit injectors in a diesel engine.

1-Radiator frame with attachments, 2-Bolt (4pcs. Torque 8Nm), 3-Bolt (2pcs. Torque 20Nm), 4-Bolt (8pcs. Torque 20Nm),

Remove and set aside coolant expansion tank
- Remove the filler tube of the windshield washer reservoir and headlight cleaner
-Unscrew screws 4
- Screw the guide rods into the right and left side member (2 each)

-Unscrew screws 2 and 3 (left and right)
- Disconnect the intercooler pressure hoses
- Using the guide pins, move the radiator frame forward by approx. 15 cm in the -arrow- direction.

-Tighten the hoses and wires.

If there are no guide rods, the radiator frame can be carefully placed on the pads, choosing their height. The photo shows the approximate position of the radiator frame mounted on the pads.

Removing the nozzle:
-Remove intake manifold
-Remove the casing and also the cylinder head cover
-Turn the crankshaft with a key so that a pair of cams, respectively installed or removed, evenly points up. If there is no key to turn the crankshaft, you can do it differently. Jack up the front wheel of the car. Engage top gear. Slowly rotate the wheel with your hands until the cams are in the desired position.

- Loosen the locknuts of the adjusting bolts -1- and unscrew the bolts until the corresponding rocker arm rests on the pusher spring of the unit injector

-Unscrew the fixing bolts -2- of the rocker shaft from the outer part inwards and remove the rocker shaft
- Unscrew the fixing bolt -3- of the block and remove the block
- Pry up the injector connector with a screwdriver. To avoid skewing, support the connector on the reverse side with light finger pressure.
-Insert the puller instead of the clamping block into the side cutout of the unit injector

If there is no puller, you can make it yourself. For example, as shown in the photo.

- Using a gentle tapping motion, remove the unit injector upwards from its seat in the cylinder head.

Installing the pump nozzle

1-20 Nm + tighten 1/4 turn (90°), 2- locknut, 3- adjusting bolt (replace at each disassembly), 4- rocker shaft with rocker arm, 5- block, 6- 12 Nm + tighten by 3 /4 turns (270°), 7- pump nozzle, 8- O-rings, 9- thermal insulation, 10- retaining ring.

When installing a new unit injector on the engine, it is mandatory to replace the corresponding adjusting bolt in the rocker arm as well. New nozzles in the kit come with o-rings and heat seal installed. If an old injector is installed, then it is necessary to replace it with new O-rings and a thermal insulator. Be careful not to twist the rings.

- Lubricate the rings with oil and very carefully install the nozzles into place in the engine cylinder head

- It is necessary to insert the pump-injector into the seat by uniform pressing until it stops

- Insert the clamping block into the side cutout of the unit injector

Attention!

If the unit injector is not positioned at right angles to the retainer, then the fastening screw may loosen after a certain time, which will lead to irreversible damage to the unit injector and seat.

- Screw the new mounting bolt into the block so that you can slightly turn the unit injector

- Install the template as shown between the bearing seat and the unit injector

- Rotate the unit injector body by hand relative to the template

Useful advice!

If you do not have a template available, then before removing the nozzle, measure the gap between the nozzle and the bearing seat (by selecting a plate of a certain thickness). In the figure, the arrow indicates the location of the gap measurement.

- Correct, if necessary, the position of the nozzle and tighten the mounting bolts. Tightening torque 12Nm followed by 270°(3/4 turn)

- Reinstall the rocker shaft and carefully tighten the new bolts

– Tighten the inner bolts first, then both outer bolts. After that, tighten in the same sequence with a torque of 20 Nm + tightening by 90 ° (1/4 turn)

- Install the indicator on the adjusting screw of the nozzle, as shown in the figure

- Rotate the crankshaft in the direction of engine rotation until the rocker roller stops at the top of the drive cam. The roller side (arrow A in the figure) is at the highest point, the indicator (arrow B in the figure) is at the bottom point

- After that, you need to remove the indicator

- Then unscrew the adjusting screw from the stop back by 180 °

- While holding the screw in this position, tighten the locknut to 30 Nm

- Insert the connector of the unit injector into place and fasten the engine cylinder head cover.

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Welcome!
Are you looking for instructions for replacing injectors in an engine on fuel-injected cars of the Samara family? If yes! In this case, today we will get acquainted with the detailed instructions for replacing injectors. For clarity, the process of replacing the injectors will be supported by photographs, and at the end of the article you will find a short video clip that talks about how quickly you can remove the injectors from the car.

Summary:

Where are the injectors located?
The nozzles themselves are located on the fuel rail in the amount of four pieces, that is, one nozzle sprays fuel strictly on one cylinder. Below is a photo of the same fuel rail and injectors that are located on it. Injectors are indicated by red arrows.

When should injectors be changed?
They must be replaced if:

• The engine of your car has started to run worse.
• And also if, when the engine is running, the fuel consumption of your car has increased.
• Even with a malfunction of the injectors, the engine usually starts to start poorly.
• After starting, the engine may also be unstable at idle.
• It is also possible that your car's engine will start to idle at higher speeds.
• And finally, with faulty injectors, the content of toxic substances in the exhaust gases increases.

How to replace nozzles on VAZ 2108-VAZ 21099?

Withdrawal:

Note!
All four nozzles are removed and installed identically, so for clarity, we will show the removal of only one nozzle!

1) At the very beginning of the operation, remove the fuel rail from your vehicle. (How to remove the ramp, see the article: "")

2) When the ramp is removed, put it on a flat surface and then disconnect the wire block from the nozzle you need.

Note!
In order to disconnect the wiring block, squeeze the spring clip that secures it and only then disconnect it!

3) Now, using a screwdriver, move the metal retainer in the direction of the ramp that secures the fuel injector.

Note!
It is not necessary to completely remove the latch from the ramp, just move it to the side!

5) Next, check the condition of the sealing ring of the injector body, and the sealing ring of the spray part of the fuel injector, for this:

Picking up a screwdriver, use it to pry both o-rings and check their condition.

Note!
If the rings are in good condition, then in this case they can not be thrown away, but left in reserve and later used on a new nozzle. Before installing the old rings, be sure to lubricate them with engine oil!

Installation:
The installation of new injectors occurs in the reverse order, that is:

1) First check the condition of the injector O-rings.

Note!
The condition of the rings is checked only if you are going to install a used nozzle on your car!

3) And finally, a block of wires is connected to the fuel injector, and after connecting, the fuel rail is installed in its place.

Additional video materials:
Below you will find a video clip in which the replacement of fuel injectors will be carried out in detail. And the most important thing is that the replacement will be carried out in a fast mode, that is, without removing the throttle assembly, in general, watch the video:

Since today the fuel is not of the highest quality, many owners need to make a replacement or. Injectors fail due to dirt in the fuel and a variety of impurities. You can understand that they work poorly by the behavior of the engine (loss of power, increased fuel consumption, etc.).

Before dismantling the injectors on the VAZ-2114, you will need to relieve the pressure in the fuel rail. The process is performed by disconnecting the connectors with wires from the fuel pump and then start the motor. The machine should work in this position until it stalls. The procedure must be repeated until the car can be started.

Disconnect the connector with wires from the fuel pump

Withdrawal:

1. It is necessary to dismantle the pipe from the air filter;
2. Disconnect the wires from the injectors;

   Disconnect the electrical connector from the fuel rail

3. and throttle position
4. Remove the vacuum hose from the fuel pressure regulator.
5. Now you need to unscrew the pipes for the supply of gasoline.

   Unscrew the fuel lines

6. It is recommended to remove the gas cable as well, so it will be more convenient to carry out the work further.
7. Next, you need to unscrew the plate that holds the fuel hoses;

   Using a screwdriver, unscrew the bracket on which the fuel pipes are attached.

8. Now you need to dismantle the fuel rail and carefully remove it from the car. In this case, the nozzles must be directed upwards;

   Removing the fuel rail

9. Now you need to remove the nozzles themselves by disconnecting the brackets that hold the electrical connectors and the nozzle itself.
10. Thus, the nozzles will be removed and they can be replaced.

    Remove the injector from the fuel rail hole

    
    

    Important! If the nozzle is to be washed, it is not recommended to put it in a dirty place.

11. It is better to close the ramp and the holes in it with something so that dirt and other objects do not get there.

Replacing the nozzle is quite simple. When the old spare part is removed, install a new one and fix it with a spring washer. After that, it will be possible to put the ramp in its place.

Video about removing and installing injectors

It is important to remember that when dismantling and installing nozzles, you should be extremely careful.

Service workers are always advised to adhere to the following points when replacing:

1. Do not damage the nozzle when replacing.
2. It is forbidden to disassemble the nozzles for repair.
3. Care must be taken not to get oil inside.
4. It is strictly forbidden to immerse parts in any detergents. They have electrical connections in the middle.
5. There is no need to rush to part with money for new parts, the problem may be solved by simply flushing the channels.
6. To do this, it is recommended to watch a video on proper flushing.

Video about proper flushing of nozzles

Symptoms to replace

Dismantled nozzles

There are actually quite a few reasons why injectors may not work well. And described below the most common symptoms:

1. Difficult starting of the engine in any weather;
2. The engine is unstable;
3. The engine stalls at idle;
4. High speed of rotation of the crankshaft at idle;
5. Power loss, ;
6. When you press the gas, shocks or dips may appear;
7. High consumption of gasoline;

If the nozzle is dirty or broken, it should be replaced or cleaned. There is no point in repairing it. It should also be noted that to date, nozzles cannot serve even 100 thousand km.

We clean the nozzles with our own hands using carburetor cleaning fluid

Checking old injectors

Checking injectors on the stand

You can also check not all nozzles at once, but each separately. To do this, you need to give current to the part and install a container with fuel to it. When current is applied, the valve will open and gasoline will have to squirt through the atomizer. But such a check is inaccurate and will still need to be checked at the stand.

Choice of nozzles

For more information on the choice of nozzles, see the material: "".

Different nozzles from different manufacturers can be installed on the VAZ-2114 model. Depending on this, the durability and their cost also differ.

Also the choice of nozzles also depends on the displacement and the number of valves. For 16 valve engines, the performance of such parts will be different than for. If the parts are not matched correctly, then most likely the gas mileage will be higher or the car will lose power.

Speaking of choice, preference should be given to the BOSCH brand number 0280158502. This is the serial number for .

BOSH injectors catalog number 0280158502

Injectors fail not only because of their quality, but to a greater extent their performance is affected by fuel in which there is a lot of dirt or large fractions.

Cleaning nozzles at service stations will not be cheap. Therefore, if checking and cleaning is not done by hand, then you should think about whether it might be easier to buy new parts and replace them.

Removing diesel injectors

What is a nozzle?

(second name - "injector") is a structural element of the engine injection system. Such a device is designed to supply fuel in a metered amount, further spraying it in the intake manifold (combustion chamber), i.e. creating a fuel-air mixture.Equipment of this kind is used in all injection systems of engines - both gasoline and diesel. Today, modern engines use nozzles that are equipped with electronically controlled injection. Depending on one or another method of injection, there are such types of nozzles as: electromagnetic, piezoelectric and electrohydraulic.

Trouble removing a fuel injector from a diesel engine?

Diesel engine injectors as elements of the fuel system must function correctly. Malfunctions of these parts violate the general scheme by which the diesel engine works. Many modern diesel engines equipped with a common rail fuel system have a number of serious problems with which we have discussed below.

This is mainly due to problems caused by the accumulation of exhaust gases or the consequence of moisture ingress leading to the block head. Also, on these engines, as a result of the burning of copper washers under the influence of combustion products, the atomizers are practically welded to the cylinder head. With further operation of the car, the situation is aggravated by the fact that the nozzle body begins to stick to the cylinder head.

In this case, it is impossible to remove diesel injectors on your own without damaging the fastening thread and the injector itself. We do not recommend removing the nozzle yourself, as this can lead not only to the removal of the cylinder head, but also to the purchase of a new block head. You can see what the self-removal of diesel injectors can lead to in the photo.

Trying to remove the diesel injector yourself

	Self-removal of the diesel injector. Broken injector thread. Further extraction of the diesel injector only using a special tool.
	Unsuccessful attempt to pull the soured diesel injector out of the block head.
	The thread of the diesel injector is jammed.
	When they tried to drill it, but the attempt was unsuccessful. The nozzle remained in place.

Problems when trying to get a soured diesel nozzle on your own:

Damaged or stripped threads on the injectors;

The nozzle body burst;

Souring of the nozzle in the well due to the ingress of atmospheric moisture into the well;

Coking of the nozzle due to gas breakthrough and the formation of soot in the well;

The body of the atomizer remained in the cylinder head, etc.

How to remove a diesel injector?

We carry out fast and high-quality Mercedes, Opel, Renault, Nissan and many other cars. For many services, a serious problem is the removal of 4 and 5 injectors SSang Yong Cayron, Rexton, Action, however, we dismantle them even without the need to remove the cylinder head and hood.

Removal of diesel injectors is carried out using a special tool that allows you to get the injector under any conditions of its operation.

Removed sticky injectors

Having extensive experience in we will make their removal qualitatively and with less loss. In our work, we use special hydraulic and thread cutting tools from European manufacturers.

A complete list of vehicles and engines on which we remove diesel injectors.

In Russia, as, indeed, in other countries of the former CIS, there is a huge number of car filling stations. But not every one of them sells high-quality fuel that meets all norms and standards. Most often, gasoline contains not only dirt, but also various impurities and substances. These are phenols, sulfur, various lead acids. In addition, low-quality fuel has a low octane number. Every owner of an injection car should know how to remove nozzles. This is useful knowledge that can come in handy when owning a used car.

Symptoms of clogged injectors

In the process of using the car, the nozzles tend to become clogged. On machines with a mileage of 200 thousand or more, they can fail. Often the reason for the failure of the nozzle is exposure to high temperatures. Inside, this element is covered with varnish deposits. As a result, there are problems in the process of starting the engine, the engine is troit, it is unstable in all modes. Due to these deposits and contaminants, the ability to pass fuel is severely impaired. There are problems in the process of opening and closing the nozzles. All this leads to one or more of these symptoms.

Where are located

The injectors on an injection internal combustion engine are located in the fuel rail. Their number is equal to the number of cylinders in the engine.

When to check work

The nozzles responsible for supplying fuel can be operated for quite a long time - manufacturers indicate at least 100-150 thousand kilometers. But, given the quality of the fuel and the untimely replacement of fuel filters, the need to check and clean them may come after 80 thousand kilometers.
The need for dismantling appears most often closer to 100 thousand kilometers. The nozzles are calibrated, tested, and if necessary, changed and cleaned. Sometimes the cause of unstable engine operation can be just one element. There is no need to remove all parts. This is especially true for diesel engines, where the operation process is much more complicated compared to the gasoline counterpart.

Dismantling of injectors for diagnostics

Let's see how to remove the injectors to test them. For dismantling, you will need a standard set of screwdrivers, wrenches, pliers, an injector or carburetor cleaner, and rags.

Consider the removal process using the example of VAZ engines. So, the first step is to reduce the pressure that forms in the fuel system. Most modern cars have a special pressure regulator - it is located on the fuel rail. This is nothing more than a special valve that can be pressed. As a result, the fuel from the ramp will go out, and the pressure level will begin to fall.
Gasoline is supplied to the nozzle at a sufficiently high pressure, so when working with them, precautions must be taken. A jet of gasoline or diesel fuel can cause significant damage.

When it was possible to relieve pressure, you need to remove the fuel rail. To do this, disconnect the connectors with wires. You can remove them with the help of special latches, which are an elastic bracket that you need to press. Next, use a screwdriver to shift the clamp in the direction along the ramp. After that, you can remove the nozzles.

Many car owners who do not know how to remove nozzles try to pull them out. But it's not the way to extract them. Dismantling is carried out after small turns or wiggles. Then, using a screwdriver, remove the o-rings - they are located on the nozzle sprayer on its body. It is worth remembering that these rings can only be used once - if they are removed once, they must be replaced.

Removal of diesel elements

The diesel fuel injector is also prone to failure due to fuel quality. The dismantling process in this case is different. The main feature is that this element is screwed into the motor like a spark plug. Operation of the injector at high temperatures leads to sticking of the part to the engine cylinder head.

The nozzle sticks due to moisture entering the well (where the element is installed). Further, the well is coked due to the breakthrough of exhaust gases there. Also, carbon deposits actively accumulate on the o-rings. The process of removing the fuel injector from a diesel engine, unlike a gasoline engine, requires the presence of an additional special tool and pullers. With the help of pullers, you can reduce the risk of thread damage, destruction of body parts.
After the thread has soured, it is very difficult to unscrew the part. In the process of dismantling, the nozzle body may simply burst. In this case, you only have to drill the part remaining in the cylinder head, then perform thread restoration and other manipulations. Those who do not know how to remove the injectors may need to rebuild the cylinder head. It must be remembered that the nozzle is an expensive part. You should carefully unscrew the part from its seat - this is the whole dismantling process.

Examination

There are many ways to check the injector. These are artisanal methods, as well as testing methods using special equipment. In the case of a self-test, only the opening/closing of the injector can be assessed. You can also make sure that the injector does not pour or overflow fuel. You can also evaluate the quality of the spray during a self-test. Not many people know how to check the removed nozzle, but you just need to connect the power and pass fuel or a cleaner through it.
As for diagnostics using professional stands, this equipment allows you to determine more parameters. This is the accuracy of operation, as well as the efficiency of all nozzles and each separately. This allows you to accurately and objectively evaluate the operation of the injection system.

Cleaning

We know how to remove injectors from an engine. You should also find out how the process of washing and cleaning them is carried out. There are two ways to wash them - with and without removal. A greater effect can only be achieved by flushing with removal.
The most common method involves the presence of keys for dismantling, a charged battery, two wires and terminals to them, as well as a cleaning fluid. The fuel rail is removed, and then the nozzle. Wires are connected to the latter. A bottle of cleaner is connected to the nozzle through the inlet. Then they press on the sprayer and close the wire on the battery, thereby activating the solenoid valve. You can also assemble a stand for cleaning nozzles. But it is very long and expensive.

How to clean injectors without removing

This requires a flush cylinder. It is made independently. You will also need a compressor and pressure gauge, a hose that will be connected to the fuel rail. Liquid for cleaning nozzles is poured into the flushing cylinder, the cylinder is connected to the system. Next, start the engine and turn on the compressor. Cleaning will be completed when all the liquid is produced.

Here's how to flush the injectors without removing them. The disadvantage of this technique is that there is no way to control the level of pollution, as well as the degree of purification. But this operation requires the least time and effort.