Fuel pump — removal and installation (Sierra)

Fuel pump adjustment

Dimensions of the mandrel for setting the crankshaft to the TDC position

Adjustment

Adjusting the maximum number of revolutions

1. Check whether the accelerator pedal and the elements that transmit its movement move freely.

2. Start the engine and warm it up to normal operating temperature.

3. Bring the engine to maximum speed.

Warning! Do not exceed the maximum permissible engine speed; the engine should be at maximum speed for no more than 5 seconds.

4. If the maximum speed differs from the recommended one (see subsection 3.2.1.2.1), then it is necessary to adjust it using the adjusting bolt 1 (see Fig. Adjusting the fuel pump).



5. Check the time it takes for the engine speed to decrease from maximum to idle (no more than 5 seconds). If this time is longer, then the idle speed and residual flow rate that prevents the engine from shutting down should be adjusted.

Adjusting idle speed and residual flow

6. Install a 4 mm thick plate between the residual flow adjustment bolt (3) (preventing engine shutdown) and the accelerator (fuel metering) lever (2) (see Fig. Fuel pump adjustment).

7. Install a 20 mm thick plate between the idle speed lever (5) (see Fig. Adjusting the fuel pump) and the limit bolt.

8. Set the position of the residual flow adjustment limit bolt so that the engine speed is 900±100 rpm.

9. Remove the 20mm thick plate. The idle lever should return to contact with the adjustment bolt.

10. Remove the 4mm thick plate.

Set the idle speed adjustment bolt so that the engine speed is 870±20 rpm.

Check the engine behavior when the accelerator pedal is released abruptly. If the time for the speed to decrease is too long, or too short and the engine stops, the adjustment should be repeated.

If the engine still stalls, tighten the residual flow adjustment bolt 1/4 turn if the engine speed decreases too slowly, or loosen it 1/4 turn if the engine speed decreases too quickly.

Caution: Do not tighten or loosen this bolt more than 1/4 turn.

Removal

1. Disconnect the ground wire from the battery.

2. Unhook the spring clips securing the upper timing case.

3. Install the vehicle on a stationary lift.

4. Unscrew the bolt securing the lower timing belt cover, then loosen the second bolt and turn the cover downwards around the loosened bolt.



5. Lower the vehicle and remove the upper timing cover.

6. 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.

7. Disconnect the electrical wire connector from the cold engine injection advance corrector.

8. Disconnect the injection line connectors and the return and fuel dose corrector line connectors from the pump (close the openings with appropriate plugs or caps).

9. Unscrew the bolts securing the lower bracket bracket of the fuel pump. Unscrew the bolts securing the bracket to the engine cylinder block.

10. Disconnect the electrical wire connector of the engine shut-off solenoid valve (STOP valve).

11. Carefully disconnect the vacuum line between the turbocharger pressure correction valve and the intake manifold.

12. Remove the alternator drive belt.

13. Remove the plug of the inspection hole from the engine cylinder block to set piston No.1 of cylinder to TDC.

14. Disconnect the fuel, return and turbocharger pressure correction lines.



15. Using the appropriate wrench, turn the crankshaft pulley clockwise so that the fuel pump is in the 12 o'clock position and the camshaft notch is in the 8 o'clock position.



16. Turn the engine crankshaft counterclockwise to set the fuel pump to the 11 o'clock position.



17. Screw in the mandrel (1) until it stops to set the piston of cylinder 1 to TDC (see Fig. Dimensions of the mandrel for setting the crankshaft to TDC).



18. Loosen the bolt (2) 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) securing the fuel pump pulley.

19. Remove the timing belt and fuel pump pulley.

20. Remove the fuel pump from the engine cylinder 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.

1. Check whether the mandrel for installing the piston of the 1st cylinder at TDC is in the inspection hole on the side of the engine cylinder block.

2. Using the appropriate tool, install the hole in the fuel pump drive pulley opposite the hole in its housing.

3. Using Torx bolts, attach the front of the fuel pump housing to the engine block.

4. After removing the installation tool, install the pulley onto the fuel pump drive flange and lightly tighten the pulley mounting bolts.

5. Position the fuel pump installation tool in the pulley and ensure it fits into the hole in the fuel pump drive flange.

6. Install the pulley mounting bolts in the middle position of the holes in the pump drive pulley.

7. Place the timing belt on the fuel pump pulley.

8. Loosen the tensioner roller mounting bolt.

9. After the tensioner has moved automatically (under the action of the spring), tighten the tensioner roller mounting bolt.

10. Tighten the fuel pump pulley mounting bolts to the specified torque.

11. Remove the installation mandrel and fixture from the pump pulley and engine cylinder block.



12. Turn the engine crankshaft two full turns and set the fuel pump installation tool hole to the 12 o'clock position and the camshaft to the 8 o'clock position.



13. Turn the engine crankshaft counterclockwise and set the hole of the fuel pump installation tool to the 11 o'clock position.

14. Install a mandrel in the inspection hole of the engine cylinder block to install piston 1. cylinder at TDC and screw it in until it stops.

15. Carefully rotate the engine crankshaft until it rests against the installation mandrel screwed into the hole in the cylinder block.

16. Insert the fuel pump installation tools.

17. If it is not possible to insert the fuel pump installation tool into the fuel pump drive flange, then loosen the drive pulley mounting bolts and turn the pulley relative to the flange so that the installation tool can be screwed in until it stops.

18. Tighten the fuel pump drive pulley mounting bolts and recheck the pump shaft installation.

19. Remove all installation tools and the mandrel and insert the plug into the inspection hole of the engine cylinder block.

20. Install the rear bracket bracket into the fuel pump and tighten the bolts to the appropriate torque. Check that the fuel pump is properly secured.

21. Screw the fuel line connectors (injection, return, fuel supply and fuel dose regulator) to the pump.

22. Connect the accelerator pedal cable in accordance with the marking made during its disconnection.

23. Connect the electrical wire connectors of the engine shut-off electromagnetic valve (STOP valve) and the cold engine injection advance corrector.

24. Install the upper timing belt cover.

25. 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.



26. Install the alternator drive belt and tighten it.

27. Lower the vehicle and tighten the upper timing case mounting bolt.

28. Remove air from the fuel system.