Contents: Removal procedure ↧ Installation procedure ↧
Removal procedure
Caution! Do not smoke or use open flames in areas where work is being performed on the fuel system. When working on the fuel system, disconnect the negative battery cable except for those checks 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 section 6B, Power Steering Pump.
Caution! Immediately after removing the fuel lines, put the cap on the injection pump coupling to avoid contamination with dust. Even a small amount of dust can clog the injectors.
5. Remove the injection pump sprocket together with the woodruff key.
6. Remove the injection pump assembly.
Installation procedure
Important: Fuel lines cannot be reused. Reusing contaminated lines may cause damage to injectors or leaking lines.
Caution! Do not blow air from a spray bottle inside the injector couplings, injection pump and threaded connections of the pipes of the common fuel rail. If dirty, wipe the dusty area with oiled paper.
Caution! Do not wipe with napkins inside the injector couplings, injection pump and threaded connections of the pipes of the common fuel rail. If dirty, wipe the dusty area with oiled paper.
1. Install the injection pump assembly.
Tighten
Tighten the injection pump bolts to 30 Nm (22.1 ft·lbs).
2. Insert the woodruff key into the groove of the injection pump drive shaft.
3. Install the 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 ft·lbs).
8. Perform fuel bleeding. See "Pumping fuel" in this section.
