Warning: Do not disassemble or repair the fuel injection pump yourself. Fuel injection pump repairs should only be performed in specialized Bosch service centers that have the necessary equipment.
Note:
- After removing the high-pressure fuel pipes, do not allow dirt or foreign materials to enter them. When installing the fuel pipes, tighten the nuts to the specified torque.
- Remove and install parts strictly in the sequence given below to avoid fuel leaks.
- The number of times high-pressure fuel pipes can be reused without losing their reliability is limited. Only five times are old high-pressure pipes allowed to be reinstalled after they have been removed. After the sixth removal of high-pressure pipes, they must be replaced.
- When connecting the fuel hoses, refer to the figure "Location of fuel system components in the engine compartment". Do not mix up the fuel supply and fuel return hoses.
1. Disconnect the cable from the negative terminal of the battery.
2. Perform the procedures specified in the section "Before performing repair work".
3. Remove the battery and battery tray.
Removal and installation of high pressure fuel pump.
1 - fuel pipes of low pressure,
2 - fuel accumulator,
3 - fuel hoses,
4 - connector,
5 - timing belt cover,
6 - Fuel injection pump.
4. Move the fuel filter assembly to the side so that it does not interfere with further operations.
5. Remove the parts in the order they are numbered in the figure "Removing and installing the high-pressure fuel pump".
1 - bolt with fuel filter (P/N -WE01-13-VH1),
2 - fuel injection pump outlet pipe,
3 - gaskets (P/N - WE01-13-VH9),
4 - key,
5 - sealing ring (P/N - WE01-13-V72).
6. Installation of parts is carried out in the reverse order of removal.
7. Perform the procedures specified in the "After Repair Work" section.
8. Start the engine and check for fuel leaks.
Note on removing high pressure fuel lines (from the injector side)
1. Secure the injector nipple from rotating,
2. Loosen the union nut of the high-pressure fuel pipe, being careful not to turn the injector nipple.
Caution: Do not allow the nozzle nipple to rotate. This may cause fuel leaks in the future.
Note on removing the fuel injection pump pulley
1. Unscrew the two bolts securing the fuel injection pump pulley,
2. Unscrew the fuel injection pump pulley mounting nut.
3. Remove the fuel injection pump pulley using a special tool.
