Removal and installation of fuel injection pumps

Note.

: replace the part with a new one after each removal.

: use a special tool or attachments.

: apply oil.

Attention.

• Leaks in the fuel lines of a pressurized system are dangerous. Fuel can ignite and cause equipment damage, serious injury or even death. In addition, fuel can get on the skin and in the eyes of a person. To prevent this, it is imperative to perform a pressure relief procedure in the power system.
• A person carrying static electricity can cause a fire or explosion that could result in death or serious injury. Before working on the fuel system, you must remove the static charge from yourself by touching the car body.
• Touching the tip of the fuel injector with your hand or pressing it with any object may cause a malfunction. Be extremely careful when handling fuel injectors.
• When removing the fuel rail, the tightness of the fuel injectors is broken. Be sure to replace the circlips, O-rings and Teflon seals of the fuel injectors with new ones.
• Do not remove pressure sensor from fuel rail.

Removing fuel injectors

1. Relieve the pressure in the fuel system (see relevant section above).


2. Disconnect the negative battery terminal.

3. Remove the decorative engine cover.

4. Remove intake manifold (see chapter "Intake and exhaust system").

5. Disconnect the fuel pressure sensor connector.

6. Disconnect the fuel injector connectors.

7. Remove the high pressure fuel lines.

8. Remove the fuel rail.

9. Remove fuel injectors.

10. Remove spacers from fuel injectors.

Note. When removing the retaining ring from the fuel injector, be careful not to damage the injector with a tool.

11. Remove the circlip from the injector as shown.



12. Remove the O-ring from the fuel injector.

13. Remove the lock washer from the fuel injector.

Note. When stretching the Teflon seal, be careful not to damage the nozzle with a tool.

14. Remove the Teflon seal from the fuel injector:

Stretch the Teflon seal as shown.



Remove the Teflon seal as shown.

Installing fuel injectors

Installation is made in an order, the return to removal. After installation, perform the necessary operations after servicing the power system.

Please note the following when installing:

Fitting the Teflon Seal to the Fuel Injector

Note. Tools 49 D013 102, 49 D013 103 and 49 D013 104 are components of kit 49 0013 1A0.

Apply engine oil to tool 49 0013104.



Fit special tool 49 0013 104 with mark towards fuel injector.



Insert a new Teflon seal on special tool 49 0013 102.




Install special tool 49 0013 102 with Teflon ring on the tip of the fuel injector.



Using special tool 49 0013 103 push the Teflon seal towards the fuel injector.



Move the Teflon seal to the position shown in the figure, then remove special tool 49 0013 103.



Slide the Teflon seal onto the fuel injector by hand and remove special tool 49 0013 102.




Push special tool 49 0013 104 up to the edge of the fuel injector.



Hold special tool 49 0013 104 for at least 30 seconds in the position shown in the illustration to correctly position the Teflon seal on the fuel injector.

Installing the lock washer on the fuel injector

Install the lock washer in the correct direction.



After installing the lock washer, make sure it is installed correctly.

Installing the retaining ring on the retaining nozzle

Note.

• Do not insert retaining ring at an angle.
• Apply force parallel to the special tool.

Place a new retaining ring on the special tool as shown in the figure, making sure the direction of the retaining ring is correct, then press the tool against the fuel injector until it clicks.

Installing fuel injectors

Attention. If engine oil is applied to the fuel injector, it can get into the injection holes and impair the quality of the fuel spray. To prevent this, apply engine oil to the side of the cylinder head.

Apply engine oil to the threads of the fuel injector mounting holes.

Insert the fuel injectors into the mounting holes one after the other, observing the installation direction of the injectors.

Fuel rail installation

Install the fuel rail onto the fuel injectors, aligning the protrusion of the spacer with the groove of the fuel rail.



Install the fuel rail mounting bolts by screwing them in until they make contact with the fuel rail.

Tighten the fuel rail mounting bolts half a turn in the sequence shown in the figure.



Tighten the fuel rail mounting bolts an additional half turn in the sequence shown in the figure (only one turn, taking into account the previous step).

Tighten the fuel rail mounting bolts in the sequence shown in the figure to a torque of 22-26 Nm.