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303-04D Fuel Charging and Controls - Turbocharger > < Fuel Charging and Controls

Galaxy 2000.75 (04.2000-02.2006)

Fuel Charging and Controls - 1.9L Diesel - Unit Injectors Galaxy 2000.75 (04/2000-02/2006)
Removal and Installation

Special Tool(s)

Socket, Flywheel Bolt

303-502 (21-205)

Remover, Fuel Injector

310-086 (23-060)

Installer, Fuel Injector Oil Seal (Large)

310-087 (23-061)

Installer, Fuel Injector Oil Seal (Small)

310-088 (23-062)

Installer, Fuel Injector Oil Seal (Medium)

310-089 (23-063)
General Equipment
Dial indicator gauge

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
  1. Remove the valve cover.
    For additional information, refer to: Valve Cover (303-01D Engine - 1.9L Diesel, In-vehicle Repair).

  1. Disconnect the unit injector solenoid valve electrical connectors.
  1. Rotate the crankshaft until the rear pair of camshaft unit injector rocker shaft cam lobes are in an evenly upright position.

  1. Loosen the unit injector rocker arm adjusting screw locking nuts and loosen the adjusting screws until the unit injector rocker arms are no longer under tension.

  1. Using the special tool, remove the rear unit injector rocker shaft.
    • Discard the retaining bolts.
  1. Rotate the crankshaft until the front pair of camshaft unit injector rocker shaft cam lobes are in an evenly upright position.

  1. Loosen the unit injector rocker arm adjusting screw locking nuts and loosen the unit injector rocker shaft adjusting screws until the unit injector rocker arms are no longer under tension.

  1. Using the special tool, remove the front unit injector rocker shaft.
    • Discard the retaining bolts.

  1. Remove the unit injector retaining blocks.
    • Discard the retaining bolts.

  1. NOTE:
    NOTE:When installing the special tool, make sure the pair of camshaft unit injector rocker shaft cam lobes are facing away from the unit injector.
    Using the special tool, remove the unit injectors.
      CAUTION:
      CAUTION:Use extreme care when removing the O-ring seals and make sure no burrs are formed on the seat of the unit injectors.
    • Discard the O-ring seals and snap ring.

Installation

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
CAUTION:
CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines.
  1. CAUTION:
    CAUTION:The unit injectors must be carefully cleaned before installing new O-ring seals.
    CAUTION:
    CAUTION:When installing the O-ring seals avoid using a rolling movement.
    Using the special tool, install a new O-ring seal.

  1. CAUTION:
    CAUTION:When installing the O-ring seals avoid using a rolling movement.
    Using the special tool, install a new O-ring seal.

  1. CAUTION:
    CAUTION:When installing the O-ring seals avoid using a rolling movement.
    Using the special tool, install a new O-ring seal and snap ring.

  1. CAUTION:
    CAUTION:Before installing the unit injector make sure the O-ring seals are correctly installed.
    Using a suitable engine oil, lubricate the O-ring seals and install the unit injectors.

  1. NOTE:
    NOTE:Install new unit injector retaining block bolts.
    Install the unit injector retaining block.
    • Do not tighten the unit injector retaining block bolts.

  1. CAUTION:
    CAUTION:Make sure the unit injectors are aligned at right angles to the camshaft bearing pedestals. Failure to follow this instruction may result in damage to the engine.
    Align the unit injectors at right angles to the camshaft bearing pedestals.
    • Dimension "X" for the unit injector in cylinder four should be 65.2 millimeters (mm) from the edge of the cylinder head.
    • Dimension "X" for the unit injector in cylinder three should be 153.2 mm from the edge of the cylinder head.
    • Dimension "X" for the unit injector in cylinder two should be 244.6 mm from the edge of the cylinder head.
    • Dimension "X" for the unit injector in cylinder one should be 332.6 mm from the edge of the cylinder head.

  1. Tighten the unit injector retaining block bolts.
  1. Rotate the crankshaft until the front pair of camshaft unit injector rocker shaft cam lobes are in an evenly upright position.

  1. NOTE:
    NOTE:Install new unit injector rocker shaft retaining bolts.
    Using the special tool, install the front unit injector rocker shaft.
  1. Rotate the crankshaft until the rear pair of camshaft unit injector rocker shaft cam lobes are in an evenly upright position.

  1. NOTE:
    NOTE:Install new unit injector rocker shaft retaining bolts.
    Using the special tool, install the rear unit injector rocker shaft.
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of engine rotation.
    Rotate the crankshaft until the camshaft unit injector rocker shaft cam lobe for the unit injector being adjusted is approaching the highest point and the unit injector plunger is approaching the maximum stroke.

  1. Install a dial indicator gauge.
  1. Carefully rotate the crankshaft and measure the lowest point of the unit injector plunger stroke and place the camshaft in this position.
  1. Remove the dial indicator gauge.

  1. NOTE:
    NOTE:A distinct resistance will be noticed when the unit injector reaches the stop point.
    Carefully rotate the unit injector rocker arm adjusting screw clockwise until the unit injector reaches the stop point.

  1. Rotate the unit injector rocker arm adjusting screw counterclockwise through 225 degrees.

  1. CAUTION:
    CAUTION:Make sure the rocker arm adjusting screw does not move. Failure to follow this instruction may result in damage to the unit injector.
    Tighten the unit injector rocker arm adjusting screw locking nut.
  1. Repeat steps 12 to 18 to adjust the remaining three unit injectors.

  1. Connect the unit injector solenoid valve electrical connectors.
  1. Install the valve cover.
    For additional information, refer to: Valve Cover (303-01D Engine - 1.9L Diesel, In-vehicle Repair).

303-04D Fuel Charging and Controls - Turbocharger > < Fuel Charging and Controls