| : | Jul 4, 2008 |


: Do not carry or operate cellular phones when working on or near any fuel
related components. Highly flammable vapors are always present and may
ignite. Failure to follow these instructions may result in personal
injury. |
: Do not carry out any repairs to the fuel system with the engine running.
The fuel pressure within the system can be as high as 1650 bar (23,931
lb-sq-in). Failure to follow this instruction may result in personal
injury. |
: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable vapors
are always present and may ignite. Failure to follow these instructions
may result in personal injury. |
: This procedure involves fuel handling. Be prepared for fuel spillage at
all times and always observe fuel handling precautions. Failure to follow
these instructions may result in personal injury.
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: Make sure the workshop area in which the vehicle is being worked on is
as clean and as dust free as possible. Foreign matter from work on
clutches, brakes or from machining or welding operations can contaminate
the fuel system and may result in later malfunction.
|
: Always carry out the cleaning process before carrying out any repairs to
the fuel injection system components. Failure to follow this instruction
may result in foreign matter ingress to the fuel injection system.
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: Diesel fuel injection equipment is manufactured to very precise
tolerances and fine clearances. It is therefore essential that absolute
cleanliness is observed when working with these components. Always install
blanking plugs to any open orifices or lines. Failure to follow this
instruction may result in foreign matter ingress to the fuel injection
system. |
: Do not disassemble or clean inside the fuel pump, even with an
ultrasonic cleaner. Always install a new fuel pump when required.
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| . | Disconnect the battery ground cable. |
| . | Remove the crankcase vent oil separator. |
| . | Release the fuel charging wiring harness.
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| . | Remove the fuel injection pump belt cover.
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| . |
:
Remove and discard the fuel injection pump belt tensioner.
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| . |
:
Remove and discard the fuel injection pump belt. |
| . |
:
Remove the injector sound proofing.
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| Right hand (RH) high-pressure fuel supply line already removed when removing the crankcase vent oil separator. |
| . | Release the left hand (LH) high-pressure fuel
supply line.
|
| . |
Remove and discard the LH high-pressure fuel supply lines.
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| . | Remove the timing belt rear cover access panel.
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| . | Remove the fuel injection pump.
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| . |
:
Using the special tool, remove the fuel injection pump pulley retaining nut. ![]() |
| . | Using the special tool, remove the fuel
injection pump pulley. ![]() |
| . | Using the special tool, install the fuel
injection pump pulley.
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| . | Install the fuel injection pump.
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| . | Install the timing belt rear cover access panel.
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| . |
:
Install a new fuel injection pump belt tensioner.
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| . |
:
Install the new fuel injection pump belt.
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| . | Remove and discard the fuel injection pump belt
tensioner locking pin. ![]() |
| . | Install the fuel injection pump belt cover.
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| . | Attach the fuel charging wiring harness.
|
| . | Install the new left hand (LH) high-pressure
fuel supply line.
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| . | Attach the LH high-pressure fuel supply line.
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| . | Install the LH injector sound proofing.
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| . | Install the crankcase vent oil separator. |
| . | Connect the battery ground cable. |
| . | Bleed the fuel system. |