Fuel injection pump (fip) - models without intercooler

Refit

1. Thoroughly clean injector and injector seat in cylinder head.
2. Fit new sealing washer to injector and fit injector to cylinder head.

CAUTION: Domed surface of sealing washer must face towards injector.

3. Fit clamp plate to injector, align injector and clamp plate to bolt hole in cylinder head
4. Fit injector clamp plate bolt and tighten to 23 Nm.
5. Connect spill return pipe to injector.
6. Connect needle lift sensor multiplug to harness.
7. Remove plugs from injector pipe, injection pump and injector unions.
8. Clean injector pipe, injection pump and injector unions.
9. Position injector pipe to injection pump and injector, connect unions.
10. Align injector pipe to other injector pipes, fit and secure retaining clips.
11. Tighten injector pipe to injector union to 20 Nm.
12. Tighten injector pipe to injection pump union to 20 Nm.

CAUTION: To prevent damage to fuel system pipes or components, use 2 spanners when loosening or tightening unions.

13. Fit engine acoustic cover. See BODY, Exterior fittings.
14. Connect battery earth lead.

FUEL INJECTION PUMP (FIP) - MODELS WITHOUT INTERCOOLER

Service repair no - 19.30.07

Remove

1. Disconnect battery earth lead.
2. Remove engine acoustic cover. See BODY, Exterior fittings.
3. Drain cooling system. See COOLING SYSTEM - ’L’ SERIES, Adjustments.

4. Release throttle cable from throttle lever.
5. Loosen nut securing throttle cable to abutment bracket.
6. Release throttle cable from abutment bracket and position aside.

7. Loosen clip and disconnect radiator top hose from radiator.
8. Loosen clip and disconnect radiator top hose from coolant outlet elbow.
9. Loosen clip and remove radiator top hose from thermostat housing.
10. Remove FIP timing belt. See ENGINE - ’L’ SERIES, Repairs.