The workshop can check the fuel injection stream and the injector injection pressure within the range of 100 to 125 bar and, if necessary, make adjustments by replacing the adjusting washer.
The first signs of a malfunction in the injector:
- misfires;
- detonation knock in one or more cylinders;
- engine overheating;
- loss of engine power;
- excessively strong black thick smoke in the exhaust gases;
- high fuel consumption;
- increased blue smoke when starting a cold engine.
High pressure fuel pump (injector pump) (2.0L engine)
Removal
p8a. Bolt with a non-falling washer or with a non-falling locking element; 10. O-ring. Always replace, lubricate before installation; 11. Threaded plug; 13, 13a. Mounting bolts, 25 Nm.; 16. Damper of the high-pressure fuel pump speed controller. Only in case of manual transmission; 19. Mounting bolt, 45 Nm (has a left-hand thread) 54–57. High-pressure fuel lines, 10–20 N·m.; 78. Sealing ring. Replace each time; 80, 82, 83. Fuel lines (For type 202, install fuel lines together with quick-acting valves); 023. Locking bolt (tool). To block the high pressure fuel pump; 027. Slotted key (tool). To rotate the high pressure fuel pump in a disassembled state
1. Remove the air cleaner cross pipe.
2. Clean the fuel lines outside.
3. Unscrew the high-pressure fuel line (54) connecting the injector and the high-pressure fuel pump, remove the holder by removing the spring clips and put it aside. Do not change the curved shape of the fuel line.
Caution! To loosen the union nuts on the high-pressure fuel lines, you need an open-end ring spanner, type HAZET 4550-14 with 1/4 drive and extension. 1/4 means that the edge length of the square hole on the key insert is 1/4 inch.
4. Remove the fuel drain lines (50) from the injector. Pull out the plug (52) from the fourth cylinder injector.
5. Unscrew the nozzle (30) using a SW 37 socket wrench fitted with a very long nozzle.
6. If present, pull out the sealing bushing.
7. Remove the injector gasket (53).
Installation
1. Install a new injector gasket (113).
2. If present, insert the sealing sleeve (109) into the threaded ring (112).
3. Screw in the injector (114) and tighten it firmly to a torque of 30 Nm. Additionally shown parts: 70 – cylinder head, 71 – cylinder head gasket, 110 – pre-chamber.
4. Fit the fuel leakage drain line.15. Screw the high pressure lines onto the injector and pump and secure the holder with spring clips.
5. Install the air filter cross pipe.
Engines 2.2 / 2.5 l
Removal
1. Remove the air cleaner cross pipe.
2. Unscrew the cover (6/1) of the cylinder head cover.
3. Using suitable pliers, pull the fuel drain lines onto the injectors to drain any leaking fuel.
4. Unscrew the high-pressure fuel lines from the injectors and the injector pump, remove the spring clamps from the holder and set aside. Do not change the curved shape of the fuel line.
Please note: To loosen the union nuts on the high-pressure fuel lines, an open-end ring spanner, such as HAZET 4550-14, is required.
5. Unscrew the nozzle (50) using a SW27 socket wrench with a long nozzle.
6. Remove the injector gasket (50/6).
Installation
1. Insert a new injector gasket.
2. Screw in the injectors and tighten them securely to a torque of 40 Nm.
3. Install pipes to drain leaking fuel.
2.2L engine
1. Screw to the nozzle and pump (10) with a torque of 10–20 Nm (approximate value) high pressure fuel lines from 55/1 to 55/4. To avoid bending of the lines, it is necessary to install fastening spring clamps (56).
3. Install the cylinder head cover housing.
4. Install the air filter cross pipe.
2.5L engine
1. Screw to the nozzle and pump (10) with a torque of 10–20 Nm (approximate value) high-pressure fuel lines from 55/1 to 55/5. To avoid bending of the lines, it is necessary to install the fastening spring clamps (56) in accordance with the drawing.
3. Install the cylinder head cover.
4. Install the air filter cross pipe.