Contents: Removal ↳ Installation ↳
Removal
Disconnect the ground cable from the battery. Release the spring clips securing the upper timing case. Place the vehicle on a stationary lift. Unscrew the lower timing case mounting bolt, then loosen the second bolt and rotate the case downwards around the loosened bolt. Lower the vehicle and remove the upper timing case. Mark the position of the accelerator pedal cable on the fuel pump lever and unhook the cable from it. Unscrew the lever mounting bolt and remove the cable.
Disconnect the electrical wire connector from the cold engine injection advance corrector. Disconnect the injection pipeline connectors and the return and fuel dose corrector pipeline connectors from the pump (close the openings with appropriate plugs or caps).
Remove the bolts securing the lower bracket of the fuel pump. Remove the bolts securing the bracket to the engine cylinder block. Disconnect the electrical wire connector of the engine shut-off solenoid valve (STOP valve). Carefully disconnect the vacuum line between the turbocharger pressure correction valve and the intake manifold. Remove the alternator drive belt.
Remove the plug of the inspection hole from the engine cylinder block to set the piston of cylinder 1 to TDC.
Disconnect the fuel, return and turbocharger pressure correction lines. Using the appropriate wrench, turn the crankshaft pulley clockwise so as to set the fuel pump to the 12 o'clock position (see Fig. 2E.11) and the camshaft cutout to the 8 o'clock position.
Turn the engine crankshaft counterclockwise to set the fuel pump to the 11 o'clock position (see Fig. 2E.11)
Screw the mandrel in until it stops (see Fig. 2E.12) to set piston 1 of cylinder to TDC (see Fig. 2E.13).
Loosen the bolt (2. Fig. 2E.14) securing the tensioner roller of the fuel pump drive toothed belt, loosen the toothed belt and tighten the bolt securing the tensioner roller. Unscrew the three bolts (1. Fig. 2E.14) securing the fuel pump pulley. Remove the toothed belt and the fuel pump pulley. Remove the fuel pump from the engine block.
Installation
Attention: When installing a new fuel pump, remove the plugs (plugs) that close the holes in the fuel lines and pour diesel fuel into the pump to facilitate the removal of air from it.
Check whether the mandrel for setting the piston of cylinder 1 to TDC is in the inspection hole on the side of the engine cylinder block. Using the appropriate device (see Fig. 2E.14), install the hole in the fuel pump drive pulley opposite the hole in its housing.
Using Torx bolts, secure the front of the fuel pump housing to the engine block.
After removing the installation tool, install the pulley onto the fuel pump drive flange and loosely tighten the pulley mounting bolts. Position the fuel pump installation tool (see Fig. 2E.14) in the pulley and make sure it fits into the hole in the fuel pump drive flange. Install the pulley mounting bolts in the middle position of the holes in the pump drive pulley (see Fig. 2E.14).
Place the timing belt on the fuel pump pulley. Loosen the tensioner pulley mounting bolt.
After the tensioner has moved automatically (under the action of the spring), tighten the tensioner roller mounting bolt. Tighten the fuel pump pulley mounting bolts to the appropriate torque.
Remove the installation mandrel and the fixture from the pump pulley and the engine cylinder block. Turn the engine crankshaft two full revolutions and set the hole of the installation fixture of the fuel pump to the 12 o'clock position (see Fig. 2E.11), and the camshaft to the 8 o'clock position. Turn the engine crankshaft counterclockwise and set the hole of the installation fixture of the fuel pump to the 11 o'clock position (see Fig. 2E.11).
Install a drift for setting piston 1 of cylinder 1 to TDC in the inspection hole of the engine cylinder block and screw it in until it stops. Carefully rotate the engine crankshaft until it rests against the installation drift screwed into the hole of the cylinder block. Insert the installation tools of the fuel pump. If it is impossible to insert the device for installing the fuel pump into the fuel pump drive flange, loosen the bolts of its drive pulley and turn the pulley relative to the flange so that the installation tool can be screwed in until it stops. Tighten the bolts of the fuel pump drive pulley and check the installation of the pump shaft again. Remove all installation tools and the drift, and insert the plug into the inspection hole of the engine cylinder block. Install the rear bracket clamp into the fuel pump and tighten the bolts of its fastening to the appropriate torque. Check the correct fastening of the fuel pump. Screw the fuel line connectors (injection, return, fuel supply and fuel dose regulator) to the pump.
Connect the accelerator pedal cable according to the markings made during its disconnection.
Connect the electrical wire connectors of the engine shut-off solenoid valve (STOP valve) and the cold engine injection advance corrector.
Install the upper timing belt cover.
Raise the vehicle, turn the lower timing belt cover upward, insert the mounting bolt and tighten it and the bolt that serves as the rotation axis of the cover.
Install the alternator drive belt and tighten it. Lower the vehicle and tighten the upper timing case mounting bolt. Bleed the fuel system.