Removal procedure
Attention! Do not smoke or use open flames in areas where work is being done on the fuel system. When working on the fuel system, disconnect the negative battery cable, except for tests that require battery voltage.
1. Remove the high pressure fuel lines. See «High pressure fuel supply lines» in this section.
2. Remove the intake manifold. See Section 1B, "Engine mechanical system - 2.0 Diesel".
3. Remove the timing belt. See Section 1B, "Engine mechanical system - 2.0 Diesel".
4. Remove the power steering pump. Follow See Section 6B, Power Steering Pump.
Attention! Immediately after removing the fuel lines, put a cap on the injection pump coupling to prevent dust contamination. Even small amounts of dust can clog nozzles.
5. Remove injection pump sprocket with key.
6. Remove injection pump assembly.
Installation procedure
Important: Fuel lines must not be reused. When reused, contaminated tubes can damage nozzles or leak tubes.
Attention! Do not blow air from the spray gun inside the injector sleeves, the injection pump and the threaded connections of the pipes of the common fuel rail. In case of contamination, wipe the dusty area with oiled paper.
Attention! Do not wipe with napkins inside the injector couplings, injection pump and threaded connections of the pipes of the common fuel rail. In case of contamination, wipe the dusty area with oiled paper.
1. Install injection pump assembly.
Tighten
Tighten injection pump bolts to 30 Nm (22.1 lb-ft).
2. Insert the slotted key into the groove of the injection pump drive shaft.
3. Install injection pump sprocket.
4. Tighten the injection pump sprocket nut by hand.
5. Align the mark on the sprocket with the mark on the rear timing belt cover.
6. Install and align the timing belt. See Section 1B, "Engine mechanical system - 2.0 Diesel".
7. Tighten the injection pump sprocket nut.
Tighten
Tighten the fuel injection pump sprocket nut to 70 Nm (51.6 lb-ft).
8. Perform fuel bleeding. See «Fuel pumping» in this section.