| : | Sep 4, 2006 |
: 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.
|
: 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.
|
| . | Disconnect the battery ground cable. |
| . | Remove the engine cover. |
| . | Clamp the exhaust gas recirculation (EGR)
coolant hoses to minimize coolant loss. ![]() |
| . | Disconnect the coolant hoses.
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| . | Remove the EGR coolant cross-over pipe.
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| . | Remove the injector sound proofing.
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| . | Release the knock sensor (KS) harness from the valve cover. |
| . | Release the glow plug harness from the valve
cover. ![]() |
| . | Disconnect the fuel injector electrical
connectors. ![]() |
| . | Release the engine wiring harness.
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| . | Release the fuel charging wiring harness.
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| . | Disconnect the breather line.
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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. ![]() |
| . |
:
Install a new fuel injection pump belt tensioner.
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| . |
:
Install the new fuel injection pump belt.
|
| . | Remove and discard the fuel injection pump belt
tensioner locking pin. ![]() |
| . | Install the fuel injection pump belt cover.
|
| . | Attach the fuel charging wiring harness.
|
| . | Secure the engine wiring harness. |
| . | Connect the fuel injector electrical connectors. |
| . | Secure the glow plug wiring harness. |
| . | Secure the KS wiring harness. |
| . | Install the injector sound proofing.
|
| . | Connect the breather line.
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| . | Install the EGR coolant cross-over pipe.
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| . | Connect both EGR coolant cross-over pipe hoses.
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| . | Connect the battery ground cable. |
| . | Check and top-up the coolant. |