Attention: Do not allow dirt to enter the path of the power system!
Attention: Remember that nozzles are precision equipment and should be handled with extreme care!
Attention: Before working on the fuel supply system on models equipped with engines with the system «Common Rail», it is necessary to wait approximately 1 minute after the ignition is switched off - during this time the pressure in the fuel path automatically decreases!
Z19DT engine (H)
1. Disconnect the wire from the negative terminal of the battery (see chapter 5) and remove the engine cover (see chapter 2).
2. On the Z19DT engine, remove the 4 mounting bolts (see illustration 17.2a) and disconnect the wiring from the glow plugs. On the Z19DTH engine, simply disconnect the wiring (see illustration 17.2b)
17.2a Connectors for electrical wiring of candles (2) incandescent (Z19DT engine) 1 Mounting bolts
17.2b Spark plug connector (2) incandescent (Z19DTH engine): 1. High pressure fuel lines
3. Turn out 8 union nuts and remove fuel lines of a high pressure from a fuel-distributing highway to atomizers.
Attention: When loosening the nuts, hold the nozzles with a second open-end wrench!
4. The nozzles are removed using special tools EN47632 and KM-328-B, first disconnect the lines / hoses of the lubrication system, unscrew 4 nuts and remove the nozzles with mounting brackets.
5. Before installing the injectors, properly clean the seats for their installation. Installation is carried out in the reverse order of removal. Replace all seals.
Z30DT engine
6. To remove the injectors, it is necessary to remove all lines and assemblies located on top of the engine that prevent the removal of cylinder head covers.
7. Remove the cover of the heads of 1 - 3-5 cylinders, turn out and remove together with the gaskets 4 bolts of the oil lines (see resist. illustration), unscrew the 3 nuts of the injector brackets, remove the 2 brackets and remove the injectors. If necessary, repeat the operations for the nozzles of the second head.
17.7 Staples (2) injector mounts (3) (Y30DT engine): 1. Oil lines
8. Old injector gaskets may remain in the seats - remove them with a suitable tool. Clean the inner surfaces of the sockets and install new gaskets in them (see resist. illustration).
17.8 Fitting a new seal (3) into the landing (4) nozzles (Y30DT engine)
9. Further installation is carried out in the reverse order of removal.
Y20DTH/Y22DTR engines
10. Remove the camshaft (see chapter 2).
11. Remove double pushrods (see resist. illustration) valves, remember the position for their installation.
17.11 Double tappets (1) valves (motors Y20DTH/Y22DTR) arrows indicate mounting marks
12. Carefully disconnect the 4 hoses of the lubrication system, then remove the bolts (see resist. illustration) fastening the inlet channels of the injectors, slightly lift the channels and pull them out of the cylinder head, remove the sealing gaskets of the injectors.
17.12 Bot (1) fixing the inlet channel of the nozzle (motors Y20DTH/ Y22DTB): 2. Sealing gasket
13. Screw the KM931 tool onto the nozzle (see resist. illustration), attach the KM-328-B tool to it and carefully pull the nozzle up. Repeat the operation for the remaining injectors. Old gaskets may remain in the housings - remove them with a suitable tool.
17.13 Removing the nozzle (3) from the nest (motors Y20DTH/Y22DTR): 1. Adaptation KM-328-B; 2. Adaptation KM-931; 4. Sealing gasket
14. Before installing the injectors, replace all gaskets, clean the surfaces of the seats and install the injectors - the spherical protrusion on each of the injectors must enter the corresponding groove on the cylinder head.
15 To install the inlet channels of the injectors, special tools KM-6318-1 and KM-6318-2 must be used to avoid damage to the gaskets (see resist. illustration) and secure them using the bearing cap bolts on the second support (between the first and second cylinders) camshaft, while the stopper (6) should be on the second cylinder side. Slide the KM6318-2 tool in the direction indicated by the arrow until the stopper stops in the KM-6813-1 tool.
17.15 Installation of devices KM6318-1 (1) and KM-6318-2 (2) to the second pillar (3) camshaft (motors Y20DTH/Y22DTR): 1. Sealing gasket; 2. Device KM-6318-1; 3. Device KM-6318-2; 4. Sliding surface; 5. Mounting bolts; 6. Stopper; 7. Threaded holes of camshaft bearings
16. Replace gaskets (see resist. illustration) inlet channels of the nozzles, lubricate the gaskets with silicone grease (white color). Install the inlet channels of the first and second cylinders on the sliding surfaces of the devices and push them all the way to their seats in the cylinder head (arrow A). Disengage the device from the channels by sliding it to the side (arrow B).
17.16 Installation of the inlet channel of the first cylinder (motors Y20DTH/ Y22DTR)
17. Remove and reinstall 4 leg fixtures (between 3 and 4 cylinders) camshaft and install the inlet channels of the nozzles of 3 and 4 cylinders. Remove fixtures.
18. To correctly install the inlet channel on the nozzle, you must use an L-shaped wrench with a socket head. Tighten the bolt with a wrench without using the wrench handle lever (see resist. illustration). Then tighten the bolt using the lever handle of the wrench.
17.18 Tightening the injector inlet channel bolt (motors Y20DTH/Y22DTR) - first (I) and second (II) phases
19. Further installation is carried out in the reverse order of removal.
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