- cross member 0102-D;
- lifting and hanging chain 0102-M;
- pin for fixing the pulley in a fixed position - 0188-V;
- high pressure fuel pump pulley removal kit - 0188-R;
- tubing wrench - 1603-G (4220-TD);
- plug set 0188-T;
- compression sleeve 1603-A/E/B/D [4220-T (B-J)].
Removal of high pressure fuel pump perform 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 «Gas distribution mechanism (timing)»;
- install the upper engine mount bracket, slightly tightening the mounting bolts;
- disconnect and move the wiring harness;
Pic. 4.109. Removing the fuel filter bracket: 1 - wiring harness; 2 - bracket; 3 - fuel filter
- move aside the harness bracket 1 (pic. 4.109) electrical wiring;
- disconnect the contact connectors;
- drain the liquid from the fuel filter housing and move it;
- close the holes with plugs using the tool;
- remove the bracket 2 of the filter housing;
Pic. 4.110. Removing the injection pump pulley: 1 - nut; 2, 3 - fixtures; 4 - pulley
- unscrew nut 1 (pic. 4.110) fastening the injection pump pulley using tool 2;
- remove the pulley 4 of the injection pump drive using tool 3;
- clean the fuel lines from dirt before unscrewing them;
Pic. 4.111. Removing the injection pump: 1, 6, 8 - fuel lines; 2 - fuel line connection; 3, 4 - bolts; 5 - bracket; 7 - fasteners
- apply a locking compound in place A (pic. 4.111);
- take aside fuel lines 6 and 8;
- close the holes with plugs using the tool;
- remove the 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 injection pump in the reverse order of removal, observing the following requirements:
Attention! Replace the high pressure fuel lines regularly.
- tightening elements 7 (see fig. 4.111) fasten with a torque of 22.5 Nm;
- tighten bolts 3 and 4 with a torque of 22.5 Nm;
- hand-tighten connection A;
- tighten nut 1 (see fig. 4.110) fastening the pulley with a torque of 50 Nm;
- install the fuel lines of the high pressure circuit of the power supply system and tighten the fittings by hand;
- tighten fuel line 1 (see fig. 4.111) torque 22.5 Nm using tools;
- check the tightness of the power 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.