Removal and installation of high pressure fuel pump is carried out as follows:
- take off «negative» battery terminal;
- free access to system parts from the front of the car;
- remove the radiator;
- remove the vacuum pump;
- remove the oil dipstick guide tube;
- remove the oil filter element and the filter itself with an oil cooler (works are described in the corresponding section). Drain the oil into a container;
- rotate the crankshaft in the direction of rotation until the piston of the first cylinder in the compression phase reaches the mark 15°after TDC (according to the index on the cover of the camshaft drive mechanism and the mark on the crankshaft pulley);
Pic. 150. Disconnecting the rod (1) from the control lever (2)
- Disconnect the fuel pedal drive from the regulator lever (pic. 150);
Pic. 151. Fuel filter: 1 - fuel filter holder; 2 - connecting fitting; 3 - straight pipeline; 4 - return pipeline; 5 - vacuum hose; 6 - vacuum regulator mechanism; 7 - plug connector of the electronic shut-off valve; 8 - electronic shut-off valve; 9 - fuel lines
- first disconnect the fuel lines 9 (pic. 151) from the fuel filter. At the same time, do not allow fuel to leak out. The sealing rings under the connections must always be replaced. Then disconnect the direct 3 and return 4 pipelines from the connecting fitting 2;
- disconnect the vacuum hose 5 from the diaphragm mechanism 6 of the fuel pressure regulator;
- disconnect the plug connector 7 of the electronic shut-off valve 8;
- do not bend the injection system fuel lines when disconnecting;
Pic. 152. Injection advance clutch
Pic. 153. Dismantling the injection pump (parts removed during disassembly): 1 - chain tensioner; 2 - central bolt; 3 - washer; 4 - spring washer; 5 - centering sleeve; 6 - pump mounting bolts
- unscrew bolt 1 in the center of the injection advance clutch (pic. 152). In this case, the crankshaft must be blocked from turning. Attention: the bolt has a left-hand thread. Under the bolt are a plain and spring washer (pic. 153);
- remove chain tensioner 1 (pic. 153) (see sect. 2 «Engine»);
- unscrew the pump fastening bolts 6 and remove the square nuts from the reverse side. Do not remove the top bolt;
- remove the pump back by disconnecting the fuel pedal drive from the pump regulator lever;
- when installing the pump proceed as follows (adjustment of the moment of the start of fuel injection is carried out only at the service station);
- check that the position of the piston of the first cylinder of the engine still corresponds to the 15°mark after TDC. Otherwise, turn the crankshaft with the key head until the indicated division coincides with the mark on the cover of the camshaft drive mechanism;
Pic. 154. Fixing the injection pump regulator: 1 - injection pump; 2 - locking bolt; 3 - regulator with a ledge
- unscrew the plug on the side of the pump. Turn the pump shaft with the special wrench 601 589 00 08 00 until the regulator protrusion appears in the open hole. Screw locking bolt 601 589 05 21 00 into the hole and tighten until you feel that the bolt engages in the adjuster lug. On fig. 154 shows the internal structure of the pump and the fastening of the regulator with a locking bolt;
Attention! The injection pump can be easily damaged. Once the pump has been installed and secured, the locking bolt must be removed.
- now you can start installing the pump:
- Tighten the pump flange mounting bolts to 20–25 Nm. Unscrew the locking bolt and screw the plug into the hole with a torque of 30–35 N·m;
- Connect the fuel lines one by one. Before tightening the fixing nuts, carefully «make money» them by carving. Tightening torque 10–20 Nm;
- tighten the central bolt of the injection advance clutch to 45 Nm, placing both washers under it (see above).
Further work is carried out in the reverse order of disassembly.