Contents: Removal ↳ Installation ↳
Removal
Disconnect the ground cable from the battery and protect the battery from being flooded with fuel.
Remove the alternator drive belt. Remove the air conditioning compressor drive belt.
Disconnect the four fuel supply hoses from the fuel pump and plug the holes in the disconnected hoses and in the pump with the appropriate plugs.
Disconnect the accelerator pedal cable from the fuel pump. Disconnect the cable from the thermal probe.
Disconnect the accelerator pedal cable bracket.
Disconnect the fuel pump electrical connections.
Disconnect the fuel supply and return hoses from the fuel pump.
Disconnect the hydraulic hoses from the power steering pump, placing a container underneath to collect any leaking oil.
Remove the power steering pump drive belt.
Remove the steering pump pulley.
Drain the coolant from the cooling system.
Raise the engine with a hoist and then unscrew the upper engine mount bracket.
Disconnect the flexible cooling system hose from the engine.
Remove the upper and lower timing cover.
Remove the inspection hole plug from the engine crankcase opening above the generator and install the installation rod in the opening (1. Fig. 2E.13).
Slowly turn the crankshaft in the direction of working rotation until it stops against the installation rod.
Insert a rod (8. Fig. 2E.47) with a diameter of 6 mm into the longitudinal adjustment hole of the fuel pump gear.
Insert a rod (7) with a diameter of 6 mm into the inspection hole of the camshaft gear.
Loosen the tensioner (2) and remove the timing belt (1).
Loosen the tensioner (5) of the fuel pump drive toothed belt.
Unscrew the bolts (C) securing the fuel pump gear.
Remove the rod (8) from the fuel pump gear.
Remove the fuel pump gear together with the timing belt.
Hold the fuel pump and unscrew the three bolts that secure the pump.
Remove the fuel pump.
Installation
Check whether the crankshaft rests on the installation rod (1. Fig. 2E.13).
Position the fuel pump on the engine and tighten the three bolts that secure its flange.
Install the fuel pump gear by aligning the cutouts of the pump flange and the longitudinal adjustment hole of the pump gear. Caution Do not screw in the fuel pump gear mounting bolts.
Insert a rod (8) with a diameter of 6 mm into the hole of the fuel pump gear. This rod should freely enter the hole of the gear and into the gap deep into the pump to the end of its length.
Install the fuel pump drive timing belt.
Hand tighten the fuel pump gear mounting bolts, then move the tensioner pulley toward the fuel pump drive timing belt.
Tighten the fuel pump gear mounting bolts to the appropriate torque.
Install the timing belt.
Remove all mounting rods.
Rotate the crankshaft two full revolutions in the direction of its rotation while the engine is running.
Set the crankshaft to the TDC position of the piston in cylinder No.1 using the crankshaft setting rod.
Install the dowel pins in the camshaft and fuel pump gears. If both dowel pins cannot be positioned correctly, repeat the entire pump installation procedure.
Perform the following steps to install the fuel pump in the reverse order of removal.
Fill and bleed the cooling system, fuel system and hydraulic system.
Check and adjust idle speed if necessary.