Table of contents: Fuel injection pump (models with…🠇 Fuel injection pump (models with…🠇
1. Disconnect the negative cable from the battery.
2. Cover the generator with a plastic bag to prevent fuel from spilling on it.
3. Remove the air cleaner with air ducts (see section 3).
4. Where necessary, disconnect the crankcase ventilation hoses and remove the oil separator.
5. Apply the handbrake and jack up the right front wheel of the car until it is off the ground. Support the car and engage 4th or 5th gear. This will allow the engine to turn over by turning the right front wheel.
6. Pull up the special clamp, loosen the spring clamps and remove the front section of the timing belt cover.
7. Move the feed lever on the high-pressure fuel pump to the open position and disconnect the cable, passing it through a special slot (see photo). Disconnect the cable adjustment ring from the bracket.
8. Pay attention to the position of the end stop on the fast idle cable, loosen the screw and disconnect the cable (see photo). Unscrew the adjusting lock nut and remove the cable with the adjusting ring from the bracket.
9. Loosen the clamp and disconnect the fuel supply hose.
10. Disconnect the main fuel return pipe and the injector bypass return pipe from the fitting pipe.
11. Disconnect the wiring from the shut-off solenoid.
12. Unscrew the nuts of the fittings that secure the fuel injector pipes to the high-pressure fuel pump (see photo) and the injectors themselves. Remove the tubes as a whole.
13. Turn the engine using the right front wheel so that the two bolt holes in the fuel injection pump sprocket are aligned with the corresponding holes in the front plate of the engine.
14. Insert 2 M8 bolts into the aligned holes and tighten them by hand. Please note that the bolts should hold the sprocket while removing the fuel injection pump, which allows you to do this without removing the timing belt.
15. Mark the position of the fuel injection pump relative to the support bracket (see photo), which will allow it to be installed in its original position during assembly. When installing a new pump, transfer the mark from the old pump to it in order to approximately install the pump in the desired position.
16. Unscrew the 3 fastening nuts and remove the plates. Unscrew and remove the rear mounting bolt and support the fuel injection pump with a wooden block (see photos).
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17. Unscrew the sprocket nut so that the shaft cone comes out of the sprocket. Together with the plate bolted to the sprocket, the nut acts as a puller.
18. Unscrew the sprocket nut again and remove the fuel injection pump from its support bracket (see photo). Remove the woodruff key if it falls out of the groove on the shaft.
19. Begin installing the pump by installing the woodruff key (if she was filming) into the groove on the shaft.
20. Unscrew the bolts securing the puller plate to the fuel injection pump sprocket.
21. Insert the fuel injection pump into place in the sprocket, checking that the shaft key enters the groove on the sprocket. Screw the nut back into place and tighten it by hand.
22. Install the mounting nuts together with their plates and tighten them by hand.
23. Tighten the sprocket nut to the specified torque, then install the puller plate and tighten the bolts.
24. Unscrew 2 bolts and remove them from the fuel injection pump sprocket.
25. If you have not replaced the fuel injection pump, align the marks you made and tighten the fastening nuts. When installing a new pump, the valve timing must be adjusted (see section 5 or section 6).
26. Connect the fuel pipes to the high-pressure fuel pump and injectors and tighten the fitting nuts.
28. Connect the wire to the shut-off solenoid.
29. Install the fuel supply and return pipes.
30. Install the fast idle speed cable and the throttle pedal cable and adjust them accordingly sections 7 and 8.
31. Install the timing belt cover sections and secure them with spring clips.
32. Lower the car to the ground and release the handbrake.
33. Remove the plastic bag from the generator and connect the negative cable to the battery.
34. Where applicable, install oil separator and crankcase ventilation hoses.
35. Install the air cleaner with air ducts.
36. To prime the fuel, turn on the ignition to energize the shut-off solenoid, and then operate the manual primer pump on the fuel filter until resistance is felt. On early models with a Lusas CAV/Roto-Diesel filter, the manual priming pump plunger should be loosened first and then tightened again when priming is complete.
37. Turn the ignition key to position "M" and wait until the pre-glow indicator lamp goes out. Start the engine and adjust the idle speed (see section 9).
Fuel injection pump (models with turbo engines) - description
1. The injection pump installed on a model with a turbocharged engine is similar to that used on engines without turbocharging, but has some additional features.
2. A special device varies the amount of injected fuel depending on the turbocharger pressure. The pressure value is read through a hose connected to the intake manifold (see photo).
3. The electromagnetic synchronization system makes the injection earlier on a cold engine. This system is switched off by a contact actuated by the fast idle lever (see photos).
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4. All these additional devices can only be checked and adjusted by a specialist.
Fuel injection pump (models with turbo engines) - removal and installation
5. Follow the instructions given above, additionally disconnecting the boost pressure hose from the fuel injection quantity control device.
6. Installation of the fuel injection pump is carried out in reverse order. If necessary, check the synchronization of the pump operation as described below.