Before removing the injection pump, be sure to set the piston of the 1st cylinder to TDC. To do this, remove the valve cover and unscrew the plug from the top of the gearbox housing so that the flywheel is visible.
Check the crankshaft (wrench on the V-belt pulley bolts) so that the mark on the flywheel is in the position shown in Fig. 232.
Install control plate (see fig. 216) on the block head and remove the toothed belt in the manner described here.
Loosen the injection pump sprocket nuts, but do not completely unscrew them.
Remove the toothed pulley using special tool 3032 (pic. 233). By screwing in the center bolt of the fixture, apply a preload on the pulley boss. Hit the end of the center bolt with a hammer to pry the pulley boss off the tapered shaft nose.
Remove tool 3032, loosen nuts completely and remove toothed pulley.
Disconnect all fuel lines from the injection pump. To loosen the union nuts, it is best to use a split ring wrench of the appropriate size (see fig. 236).
Attention! In the design of Bosch pumps, the suction and discharge tube nuts have: the same diameters, however, the discharge tube nut is equipped with a throttle. For distinction, it is marked with the inscription «OUT". It must be replaced during installation.
Disconnect the switch control rod.
Disconnect the accelerator and starter linkage.
Loosen three screws 2 (pic. 234) fastening the flange of the high-pressure fuel pump and one bolt 1 of its fastening to the rear bracket. In Bosch pumps, in no case should the bolts indicated by arrows in the figure be unscrewed, as this can lead to displacement of the pump distributor head.
The injection pump distributor cannot be repaired, and in case of damage it must be replaced with a new one or a remanufactured one.
The injection pump is installed in the following order:
Install the pump on the bracket so that the control marks on the injection pump pulley and on the bracket match (pic. 235).
Insert the bolts and tighten them evenly one by one to a torque of 25 Nm.
Check whether the key is installed on the pump shaft, install the toothed pulley on the shaft. Tighten the fixing nuts to 45 Nm.
Connect the fuel pipes by tightening the union nuts with a torque of 25 Nm with a specially sawn wrench (pic. 236).
Turn the pump pulley so that the marks on it and on the bracket match (top arrow in fig. 237). In this position, block the pump pulley with the locating pin 2064 (pic. 237 and fig. 238).
Loosen the camshaft pulley bolts half a turn and, hitting the pulley with a rubber mallet, loosen its fit on the camshaft nose cone.
Check again if the piston of the 1st cylinder is at TDC.
Install the toothed belt in the manner given here.
Complete described here actions until the belt is tensioned.
Check and adjust the start of compression.
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