- crossbar 0102-D;
- chain for lifting and hanging 0102-M;
- pin for fixing the pulley in a fixed position - 0188-V;
- high Pressure Fuel Pump Pulley Removal Kit - 0188-R;
- tube wrench - 1603-G (4220-TD);
- set of plugs 0188-T;
- compression coupling 1603-A/E/B/D [4220-T (BJ)].
Remove the fuel injection pump in the following order:
Attention! Each time the high pressure hoses are removed, they must be replaced with new ones.
- remove the timing belt, see "Timing mechanism (Timing)";
- install the upper engine mount bracket, lightly tightening the mounting bolts;
- disconnect and move aside the wiring harness;
Figure 4.109. Removing the fuel filter bracket: 1 - wiring harness; 2 - bracket; 3 - fuel filter
- move aside the harness bracket 1 (figure 4.109) electrical wiring;
- disconnect the contact connectors;
- drain the liquid from the fuel filter housing and move it aside;
- close the holes with plugs using the device;
- remove bracket 2 of the filter housing;
Figure 4.110. Removing the fuel injection pump pulley: 1 - nut; 2, 3 - devices; 4 - pulley
- unscrew nut 1 (figure 4.110) fastening the fuel injection pump pulley using tool 2;
- remove pulley 4 of the fuel injection pump drive using tool 3;
- clean the fuel lines from dirt before unscrewing them;
Figure 4.111. Removing the fuel injection pump: 1, 6, 8 - fuel lines; 2 - fuel line connection; 3, 4 - bolts; 5 - bracket; 7 - fastening elements
- apply counter-coat at location A (figure 4.111);
- move aside fuel lines 6 and 8;
- close the holes with plugs using the device;
- remove high pressure fuel line 1;
- unscrew bolts 3;
- loosen the tightening torque of bolt 4;
- tilt bracket 5;
- remove fasteners 7;
- remove the high pressure fuel pump.
Install the fuel injection pump in the reverse order of removal, observing the following requirements:
Caution! Replace high-pressure fuel lines regularly.
- tightening of elements 7 (see figure 4.111) fasten with a torque of 22.5 Nm;
- tighten bolts 3 and 4 to a torque of 22.5 Nm;
- tighten connection A by hand;
- tighten nut 1 (see figure 4.110) pulley fastening torque 50 Nm;
- install the fuel lines of the high-pressure circuit of the fuel system and tighten the fittings by hand;
- tighten the fuel line fastening 1 (see figure 4.111) torque of 22.5 Nm using devices;
- check the tightness of the fuel system connections by starting the engine and setting the crankshaft speed to 1000 min⁻¹. Press the accelerator pedal several times, bringing the crankshaft speed to 3500 min⁻¹.