Pump-nozzle with mounting parts
1 – rocker arm axle mounting bolt; 2 – rocker axis; 3 – lock nut; 4 – adjusting screw; 5 – pump-injector; 6 – upper sealing ring; 7 – middle sealing ring; 8 – lower sealing ring; 9 – heat-insulating ring; 10 – retaining ring; 11 – cylinder head; 12 – pump-injector holder; 13 – holder mounting bolt
Installation of pump injectors
1 – adjusting screws; 2 – rocker arm axle mounting bolts; 3 – injector holder mounting bolt
1. Remove the upper camshaft drive belt cover.
2. Remove the cylinder head cover.
3. Turn the crankshaft so that the rocker arms do not press on the tappet of the injector being replaced.
4. Loosen the tightening of lock nuts 3 and unscrew the adjusting screws 4 so that the rocker arms touch the plates of the pump-injector springs.
5. Unscrew bolts 2 (see the figure Installation of pump-injectors) fastening the rocker arm axle, first unscrew the two outer bolts, then the two middle ones.
6. Remove the axle with rocker arms as an assembly.
7. Unscrew bolt 3 of the fastening and remove the pump-injector holder.
8. Using a screwdriver, disconnect the connector with wires from the pump-injector.
9. Insert a special puller into the groove of the unit injector under the holder, as shown in the figure, and remove unit injector 2 (1 – puller T10055). Mark the unit injectors to avoid mixing them up during installation.
10. Inspect sealing rings 6, 7 and 8 (see the figure Pump-injector with mounting parts), replace any cracked, torn or loose rings.
11. To install new rings, the manufacturer recommends using a set of mandrels T10056 (1 - mandrel for the upper ring; 2 – mandrel for the middle ring; 3 – mandrel for the lower ring).
12. Remove the old sealing rings carefully, being careful not to damage the seats on the injector.
13. Remove the locking 10 (see the figure Pump-injector with mounting parts) and heat-insulating 9 rings so that they do not interfere with the installation of mandrels.
14. Thoroughly clean the sealing ring seats on the injector.
15. Place mandrel 2 for the upper sealing ring onto the injector and slide sealing ring 1 onto the injector without twisting it (3 – injector pusher).
16. Install the middle and lower sealing rings in the same manner. Install the insulation and retaining rings.
17. Inspect the adjusting screw and pusher 3 of the injector: if at least one of them shows signs of wear, replace the screw and pusher.
18. Lubricate the lower end of the adjusting screw and the spherical surface of the injector plunger with grease.
19. Lubricate the injector sealing rings with a thin layer of engine oil, carefully insert the injector into the cylinder head and, gently pressing on it, insert it into the head until it stops.
20. Install the nozzle holder so that its protrusion fits into the groove of the nozzle. The holder mounting bolt needs to be replaced. Screw in the new bolt without tightening it completely.
21. It is crucial that the holder and injector are installed perpendicular to the cylinder head plane; otherwise, the holder mounting bolt may come loose, causing failure of the unit injector. To ensure that the unit injectors are installed strictly vertically, the distance a between the rear outer plane of the cylinder head and the surface of the unit injector must be maintained: 4th cylinder 64.8±0.8 mm, 3rd cylinder 152.8±0.8 mm, 2nd cylinder 244.2±0.8 mm, 1st cylinder 332.2±0.8 mm.
22. After adjusting the distance, tighten the bracket mounting bolt to 12 Nm, then tighten it another 270° (3/4 turn).
23. Install the rocker arm shaft. The axle mounting bolts need to be replaced. First screw in the two inner axle mounting bolts by hand, then the two outer ones. After this, tighten the inner bolts to a torque of 20 Nm, and tighten the two outer bolts to the same torque. Tighten the inner bolts, and then the outer ones another 90°.
24. Turn the crankshaft so that rocker arm 3 recesses the injector pusher as much as possible; this can be checked using indicator 1 (2 – pump-injector).
25. Turn the adjusting screw until it noticeably stops against the injector plunger, then another 225°, and then back it out a little, as shown in the figure.
26. While holding the adjusting screw in this position, tighten its lock nut to a torque of 30 Nm.
27. Install all removed parts in reverse order.
Tightening torques, Nm
| Lambda probe | 50 |
| Intake manifold mounting bolt | 8 |
| Fuel rail mounting screw for 1.4L, 55 and 74 kW engines | 10 |
| Thermostat housing mounting bolt | 10 |
| Rocker arm axle mounting bolt for 1.9L, 74 kW engine | 20 and turn 90° |
| Injector holder mounting bolt for 1.9L 74kW engine | 12 and turn 270° |
| Fuel line union nut | 25 |
| Fuel line bolt | 10 |