Removal and installation of the pump nozzle

Removing

Remove the upper part of the timing belt cover and the cylinder head cover.

Unscrew the locknuts of the adjusting screws a and unscrew the adjusting screws until the corresponding rocker arm rests on the pusher spring of the unit injector.



Unscrew the fixing bolts 5–1 of the roller lever axle from outer to inner using a nozzle and remove the roller lever axle (pic. 2.316).


Remove the cable connection of the unit injectors and glow plugs.

Loosen the mounting bolts B of the unit injectors using a nozzle and remove the bolts.

Remove the ball head bolt from the pump injector.



Install the puller in the bolt holes of the unit injector (pic. 2.364).

Slightly rotate axis A in the direction away from the unit injector. Tighten locknut B by hand.

By tapping, remove the unit injector with a mallet upwards from the socket on the cylinder head.

Note: Do not swap previously used unit injectors.

Installation

The fixing screws of the unit injectors must be replaced in any case.

Attention: During any work related to the adjustment of the unit injector using the adjusting screw, it is necessary to replace the adjusting screw in the rocker arm and the ball head screw of the unit injector, otherwise increased wear of these parts will occur.

Before installing the unit injector, check that the new O-rings are seated correctly.

Note: New unit injectors are supplied complete with O-rings.

Note: When installing an old unit injector, the O-rings must be replaced.

Note: O-rings must not be twisted.

Note: Lubricate the O-rings and the injector rod with oil.

Note: Check the seat for the pump injector in the cylinder head for contamination (e.g. shavings, soot, etc.), if necessary, clean with compressed air.

Very carefully insert the unit injector into the seat on the cylinder head.



Install the mounting tool with 2036/1, as shown in Figure 2.365, on the cylinder head frame.

Caution: If the unit injector is overtightened by the fastening screws, there is a risk of it being twisted. As a result, deterioration in driving performance and problems with starting the engine may occur. Therefore, the unit injector must first be pressed into the seat and only then screwed on.

Insert new mounting screws and tighten them by hand without applying force, until they stop (pic. 2.366).

Insert valve extractor with mandrel.



Press the unit injector with a valve extractor into its seat and hold it in this position (pic. 2.367).

Tighten the fixing screws of the unit injector by hand without applying force using the insert until it stops.

Tighten the new fixing screws as follows:

• stage 1 - 3 Nm;
• stage II - 90° (1/4 vol.);
• stage III - 180° (1/2 vol.).

Note: Replace adjusting screws A and unit injector ball head bolt.

Install the axle of the roller levers and tighten the new fasteners evenly in sequence 1-5 by hand (pic. 2.316).

Then tighten evenly in the same sequence from 20 Nm + tighten by 90° (1/4 turn).




Establish a micrometer as it is shown in drawing 2.368, on the adjusting screw of the pump-injector.

Rotate the crankshaft in the direction of engine rotation until the rocker arm roller is at its highest point. Roller side A is at the highest point. Indicator B is at its lowest point

Remove the micrometer.

Then screw the adjusting screw into the rocker until you feel a noticeable resistance (pump injector screwed up to the stop).



Loosen the adjusting screw from the position «twisted up to the stop» 180° (pic. 2.369).

Hold the adjusting screw in this position and tighten the locknut to 30 Nm.

Install the injector plug and install the cylinder head cover and toothed belt guard.