Removing
Attention! It is forbidden to disconnect the connectors from the injectors while the engine is running.
Switch off ignition and disconnect a wire from the negative plug of the storage battery.
Before starting any work on the fuel system, wait 30 seconds after stopping the engine.
Remove the decorative casing from the engine.
Pic. 4.69. Location of wires and connectors on the DW10TD engine: 1 - wiring harness; 2 - pump support for filling the system with fuel; 3 - support of the decorative casing of the engine; 4, 7, 8 - sensors; 5 - pin connectors; 6 - oil vapor trapping tube; 9 - fuel supply pipe
Disconnect the connectors from sensors 4, 7, 8 (pic. 4.69).
Disconnect the connectors 5 from the injectors.
Set aside the wiring harness for 1 injectors.
Take aside the tube 6 for trapping oil vapors and the pump for filling the system with fuel.
Remove pump support 2 to fill the system with fuel.
Remove a support 3 of a decorative casing of the engine.
Use a screwdriver to move the retainer up and remove the diesel return pipe.
Use SODIMAC 35 to clean the union nuts of the high pressure fuel pipes and the area around the nuts.
Pic. 4.70. High pressure fuel pipe: 1 - connecting nut, 25 Nm; 2 - high pressure fuel pipe; 3 - connecting nut, 28 Nm; A - hexagon on the nozzle
Holding the hexagons A with a wrench (pic. 4.70) on the injectors, unscrew the connecting nuts 1 fastening the high pressure fuel pipes to the injectors with the second wrench.
Unscrew the connecting nuts 3 fastening the high-pressure fuel pipes to the fuel distributor and remove the fuel pipes 2. To prevent dirt from entering, close the fuel pipes and fittings on the fuel distributor with suitable plugs.
Pic. 4.71. Nozzle fasteners: 1 - thrust pin of the nozzle mounting bracket; 2 - bracket; 3 - bolt
Remove bolts 3 (pic. 4.71), remove brackets 2 for fastening the injectors and thrust pins 1 for the brackets for fastening the injectors.
Attention! When regrinding the mating surface of the block head, the thrust pins of the injector mounting brackets must be replaced with the corresponding repair pins.
Being careful, take atomizers from a head of the block of cylinders.
Remove sealing sleeves (between injector and cylinder head).
Close the injector sockets and injector nozzles with suitable plugs.
Installation
Attention! When installing injectors, new high-pressure fuel pipes and sealing sleeves must be used.
Remove the plugs covering the injector sockets.
Install new sealing bushings on the injectors.
Install the injectors to the cylinder head.
Install the thrust pins of the injector mounting brackets, brackets and secure them with bolts, finger-tight at this stage.
Connect the diesel fuel return pipes to the injectors.
Install the high pressure fuel lines to the injectors and fuel distributor and secure them with union nuts, hand-tight at this stage.
Tighten the injector bracket bolts to 35 Nm.
Pre-tighten the connecting nut fastening bolts to 24 Nm.
Tighten union nuts 3 (see fig. 4.70) torque 28 Nm.
Tighten the connecting nuts 1 to 25 Nm.
Further installation is carried out in the reverse order of removal.
Do computer programming.
Start the engine.
Check for fuel leaks.