Preparatory work
Remove the intercooler, engine cover, underbody protection, front exhaust pipe.
Disconnect all electrical wiring, all tubes and hoses and move aside.
Remove the valve cover (if the drain tube and nozzle assembly is removed).
Removal and installation of high pressure fuel pipes
Removing
Mark the cylinder numbers and then remove the high pressure fuel lines.
Caution: Apply the marks in such a way that they are not washed off by the fuel.
Remove clamps (3 pcs.), and then remove the tubes one at a time.
Note: The illustration does not show the intake manifold for clarity.
Installation
Establish fuel pipes on all cylinders, being guided by drawing and tags put before removal.
Tighten the flare nuts on the cylinder head side only 2-3 turns, make sure that all pipes are installed to the pump, and then tighten the flare nuts on the cylinder head side and pump side, starting with the far pipe.
Install the clamps as shown in the illustration.
Insert clamp bolt (for 4 tubes) from the rear of the engine towards the front.
Removal and installation of an epiploon of a nozzle
Removing
Use a screwdriver to pry the seal off the flange and remove it.
Installation
After installing the injectors as an assembly, press in the oil seals from the outside of the cylinder head until the flange fits snugly.
Note: After removing the injector assembly, replace the oil seals with new ones (if only high-pressure fuel pipes are removed and installed, then it is not necessary to change the seals).
Removal and installation of a drain tube
Removing
Loosen and remove the set bolts and cap nuts in the reverse order of the illustration.
When loosening the union nut, hold the hex part of the drain bolt with a wrench (on the inside of the head).
Installation
Tighten the flare nuts and set bolts in the order shown in the illustration above.
When tightening the union nut, hold the hex part of the drain bolt with a wrench (on the inside of the head).
Tighten the set bolts so that the contact areas of the drain tube gasket are in the areas indicated by the arrows in the figure (pay special attention to cylinders No. 2, 4).
Note: This is to ensure that there is no contact with the valve cover.
Attention:
After installing the drain tube, be sure to check the drain tube for leaks (point 5).
After tightening the set bolts to the required torque, the contact areas of the gasket may break, but this will not affect operation.
Removal and installation of the nozzle assembly
Removing
Remove the nozzle support by pulling out and turning the nozzle assembly to the right and left.
Using a screwdriver, remove the copper washer installed in the cylinder head.
Attention: Do not disassemble the nozzle assembly.
Installation
Install the injector gaskets into the cylinder head holes.
Install the O-ring into the injector groove and insert the injector into the cylinder head.