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Injector Removal And Refitting; a small guide
Topic Started: Thu Nov 8, 2007 2:56 pm (25,356 Views)
optimusprime
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Part of things
[ *  * ]
stwat
Thu Nov 8, 2007 6:30 pm
Its a bit different on the 2.6 M103 engine.
Here's a mini guide.

The first thing to do is remove the air box. You will then see the fuel distributor and the pipes that go to the injectors.


The first thing that is different is that each injector is held in by its own separate bracket.
Posted Image

Id recommend you undo the olive nut (14mm spanner needed for this)before you undo the bracket(5mm Allen bolt) otherwise the fuel pipe and olive nut just twist.

The first three injectors are a pain to get to and you definitely need to remove air box support bracket to get to the first injector.
Posted Image

The next two are the most tricky ones to get to. I found that to get the injector out of the second one i had to remove the fuel pipe completely from the fuel distributor. The others can simply be moved out of the way.
Posted Image

The next one along was a right royal pain to get the Allen key on and even harder to get any leverage. So i used a tried and tested method of slipping a ring spanner over the end of the Allen key :D
Posted Image

Once you undo the olive nuts move/bend the pipes out of the way and undo the Allen bolt, the injectors will just pull out in one unit with the fixing brackets still attached.
Posted Image

The bracket just pulls off. The rubber seals are a bit more difficult to remove and may get damaged in the process. So i recommend getting new seals before you do the job.

As you can see there are no plastic tubes or pipes to clean like on the 16v models. The injectors slot directly into the intake manifold.

Refitting is basically the reverse although i found it easier on some to not fit the bracket until i had slotted the new injector in place.

Just a few pointers and tips there which i hope help B)

Stu
Good post but on the cis injection you first de pressurise the fuel system. Start engine and pull the fuel pump relay ,wait till engine as stoped.Now you can go about removal of the injectors. Telling you all about this ,as its my next job.
Edited by optimusprime, Thu May 28, 2015 11:14 am.
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clubman
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[ *  * ]
Thanks for the write up. Followed it today and successfully replaced all six injectors and seals. Even managed to change the air hose the cold start valve plugs into whilst everything was out of the way. Can always rely on the forum!!
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worthingmercedes
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Good Job ! The only thing we do in the garage would be change the O rings too as they can leak and go hard just a few pence it's worth it,
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clubman
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Did those along with the plastic head inserts. I tend not to scrimp on the car. Got the Bosch injectors online from Berlin for €26 and everything else from Mercedes Brighton.

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eagle3
Therapy Needed
[ *  *  *  *  *  * ]
Agree, best to change O rings as well. How much did you pay for the plastic sleeves? I decided not to change those.
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rhysmangatmotorsport
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Mangatmotorsport
[ *  *  *  *  *  *  *  *  * ]
You should always change the seals/ o rings, it's just an easy to do & worth it.
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Haris
Part of things
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£93 for a full set of 2.5-16v Bosch injectors. Plus £8.14 cashback, so £85 essentially.

http://www.carparts4less.co.uk/

http://www.topcashback.co.uk/carparts4less/

Bargain I thought, only found out because my friend bought some for his turbotechincs MK2 Golf
Edited by Haris, Wed Aug 5, 2015 11:25 am.
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clubman
Part of things
[ *  * ]
eagle3
Tue Aug 4, 2015 10:20 am
Agree, best to change O rings as well. How much did you pay for the plastic sleeves? I decided not to change those.
Plastic sleeves were £3 each + vat
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Talac2.6
Part of things
[ *  * ]
stwat
Thu Nov 8, 2007 6:30 pm
Its a bit different on the 2.6 M103 engine.
Here's a mini guide.

The first thing to do is remove the air box. You will then see the fuel distributor and the pipes that go to the injectors.


The first thing that is different is that each injector is held in by its own separate bracket.
Posted Image

Id recommend you undo the olive nut (14mm spanner needed for this)before you undo the bracket(5mm Allen bolt) otherwise the fuel pipe and olive nut just twist.

The first three injectors are a pain to get to and you definitely need to remove air box support bracket to get to the first injector.
Posted Image

The next two are the most tricky ones to get to. I found that to get the injector out of the second one i had to remove the fuel pipe completely from the fuel distributor. The others can simply be moved out of the way.
Posted Image

The next one along was a right royal pain to get the Allen key on and even harder to get any leverage. So i used a tried and tested method of slipping a ring spanner over the end of the Allen key :D
Posted Image

Once you undo the olive nuts move/bend the pipes out of the way and undo the Allen bolt, the injectors will just pull out in one unit with the fixing brackets still attached.
Posted Image

The bracket just pulls off. The rubber seals are a bit more difficult to remove and may get damaged in the process. So i recommend getting new seals before you do the job.

As you can see there are no plastic tubes or pipes to clean like on the 16v models. The injectors slot directly into the intake manifold.

Refitting is basically the reverse although i found it easier on some to not fit the bracket until i had slotted the new injector in place.

Just a few pointers and tips there which i hope help B)

Stu
I've tried to do this job today. Strip down started ok to the point of undoing the olive nuts prior to unfastening the allen bolts two of the six of them felt like either they were going to cross thread or the pipe's were going to twist and snap like brake pipes do when there corroded. There is no visible corrosion on any pipes, its just that four of the olive nuts cracked and came undone the other two just didn't feel right. Anyone experienced a similar problem or any ideas what I should do with them? I've sprayed penetrating oil into the olive nuts gave I little time and no success maybe try them again tomorrow.
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MercManCraig
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Craig
[ *  *  * ]
Could try taking the pipes off from the fuel distributor end then getting the injector and pipe out together, whack em in a mini vice and have another shot at it with a nice flare spanner. One of mine felt a bit mushy to take off but it was just the fact that the injectors in a rubber bung and it was moving about a bit in the injector retainer bracket mabob with the slack.

If it ends up damaging a pipe or injector throw me a PM. I've got a few m103 Kjet spares.
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