In order to use these tools, you need to follow the description below.
8.3.1. Removal and installation
Before removing the high pressure fuel pump, set the engine to top dead center. To do this, you need to remove the cylinder head cover and crank the engine until both valves of the first cylinder are closed, i.e. both valves should not have a gap. Further removal should be carried out using Figure 148:
Figure 148. Parts for removing and installing the fuel pump. 1. Throttle control cable; 2. Fuel lines; 3. Fuel hose; 4. Water hose; 5. Plug; 6. Plug; 7. Nut, 60-70 Nm; 8. Fuel pump; 9. Nut, 20-25 Nm; 10. Bolt, 20-25 Nm; 11. Union nut, 25-30 Nm; 12. Bolt, union nut, 25-30 Nm
- Disconnect the throttle control cable (1).
- Unscrew all fuel lines from the pump. To loosen the union nut, it is best to use a spanner of the appropriate size that has a slot machined into it to allow it to be inserted through the fuel lines.
- Wrap the connections with a thick cloth to collect any leaking fuel. Figure 149 shows the connection points of the fuel lines.
Figure 149. Fuel line attachment points (indicate with arrows)
- Disconnect the fuel hoses (3) and water hose (4) from the pump.
- Remove the plug from the fuel shut-off valve (5) of the pump.
- Remove the plug (6) from the pump wall.
- Loosen the fuel pump drive gear nut. To do this, you need to insert two bolts 35-40 mm long through the gear and screw them into the threaded holes of the console. The pump gear must be positioned correctly to tighten the bolts. Now the pump gear is closed and the nut can be released. Remove the snap ring.
- Remove the pump gear using a puller. It screws into both threaded holes. Press the middle spindle against the shaft and remove the gear.
- Unscrew the puller and remove the drive gear.
- Unscrew the pump together with the mounting console and remove it. If the pump does not unscrew from the console, then there is no need to set the injection time.
- The high-pressure fuel pump can be repaired or overhauled using normal means, and if damaged, a replacement or new pump can be installed, or the old one can be taken to a specialized workshop for repair.
When installing the pump, proceed as follows:
- Install the pump with support brackets on the engine and evenly tighten the bolts to 19-26 Nm.
- Check that the V-belt is on the pump shaft and carefully push the drive gear onto the shaft.
- Screw the nuts in and tighten to a tightening torque of 60-70 Nm.
- Both screws need to be screwed back into the console to prevent the pump from turning.
- Tighten the fuel line union nut to 25 Nm. Use a slotted socket wrench for this.
- Check again that the engine is at top dead center at all times.
- Check the valve timing as described when installing the cylinder head.
- Also carry out all subsequent work described in this chapter until the V-belt is tensioned.
- Set injection time (chapter 8.4).