Kohler KD83V16 — Injector removal and installation (SL 205)
Repair & overhaul
For the Kohler KD83V16, from the Kohler service manual.
Applies to: Kohler KD83V16, Kohler KD83V16 engine
Before you start
- Replace all sealings.
- Lethal injury by flammable fluids under high pressure up to 2000 bar.
Procedure
- Remove electrical contacts from injector.
- Take off high pressure pipe 5 from adaptor 9.
- Remove retaining plate 2 with screws 3.
- Remove clamp 7 by opening screw 6.
- Remove injector 4 with extracting tool.
- Clean carbon from injector seat on sleeve.
- Lubricate sleeve and injector O-rings with Molykote DX or Castrol Optimol Paste White.
- Position injector with connection upwards; install clamp, retaining plate and high pressure pipe.
- Tighten per tightening sequence.
Tools required
- Injector extractor Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Pre-tighten nut 23 Nm
- Clamp 60 Nm
- Distributor block nut 189 Nm
- Injector nut 150 Nm
- Electrical connection 0.5 Nm
Full service-parts list: Kohler KD83V16 →
Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.