Contents: Removal 🠛 Installation 🠛
Caution! Before performing any work, connect the aftermarket diagnostic tool, establish communication with the injection system ECU and ensure that the fuel rail is not under pressure.
Take precautions against possible burns from hot fuel.
Removal
Disconnect the battery.
Install the engine support crossbar for hanging Mot. 1453.
Set the crankshaft to the TDC position of the piston of the 1st cylinder and lock the shaft with the locking tool Mot. 1054.
Remove:
- right front wheel and mudguard;
- pendulum suspension;
- timing mechanism drive cover;
- install the high pressure fuel line using tool Mot. 1383;
- ramp.
Seal the holes with protective plugs.
Disconnect the return line from the high-pressure fuel pump and seal the openings with protective plugs.
Remove the rear bracket securing the fuel injection pump.
Install tool Mot. 1200-01 on the pulley.
Loosen the high pressure pump gear nut.
Install puller Mot. 1525 with adapter Mot. 1525-01 on the injection pump pulley and press off the pulley assembly.
Loosen the fuel injection pump mounting nuts while holding bolts 1.
Installation
Installation is carried out in the reverse order of removal.
Note: Be careful not to put any load on the high pressure fuel line.
Screw on the nuts securing the high-pressure fuel lines to the high-pressure fuel pump and injectors, then from the rail side. Tighten the nuts to the specified torque in the same order as for preliminary tightening.
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Tighten the high pressure fuel rail mounting bolts.
Each time the high-pressure fuel pump is removed, the fuel return line 2 must be replaced.
Install:
- pendulum suspension;
- rear mounting bracket 1 fuel injection pump.
Tighten the cylinder head mounting bolts first, then the ramp mounting bolt.
For fuel injection pump SRZ
Fill the system with fuel using a hand priming pump.
After performing any work, make sure there are no fuel leaks. Let the engine idle until the electric cooling fan turns on, then increase the engine speed several times at idle.
For fuel injection pump SR1
Fill the system with fuel:
- close the tap (R);
- turn on the low pressure pump by placing the card in the reader in the 2nd fixed position several times;
- start the engine;
- open the tap (R) (when the tap is open, the two color marks on it align).
Note: Some vehicles do not have this valve. In this case, the fuel system refilling operations are not performed.
After performing any work, make sure there are no fuel leaks. Let the engine idle until the electric cooling fan turns on, then increase the engine speed several times at idle.