- remove the air filter;
- remove the upper protection of the toothed belt;
- remove the cylinder head cover;
- set the engine to TDC. To do this, remove the cylinder head cover and unscrew the plug located at the top of the gearbox so that the marks on the flywheel are visible;
Pic. 415. The upper figure shows the adjusting gauge 1 mounted on the camshaft. The lower figure shows how the flywheel with the TDC mark should be located
- turn the crankshaft (using a key put on a pulley bolt) so that the mark on the flywheel is in the position shown in Fig. 415.
- install the adjusting gauge for the camshaft and remove the V-ribbed belt, as described in paragraph 17.4.1. Remove the guide roller;
- loosen the injection pump gear nut, but do not unscrew it completely;
Pic. 474. Removing the gear wheel of the injection pump using a special tool. Hit the head of the bolt with a plastic or rubber mallet in the direction of the arrow to move the gear wheel from its tapered attachment point
- remove the gear wheel using special puller 3032. To do this, install the puller on the gear wheel (pic. 474). Tighten the middle bolt of the puller so that the puller is pressed against the surface of the gear, and then remove the gear by hitting the end of the middle bolt with a plastic or rubber mallet;
- remove the puller, unscrew the nut from the end of the shaft and remove the gear;
- disconnect all fuel lines from the injection pump;
- disconnect the plug connector of the fuel cutoff valve;
- disconnect the fuel control cable;
- mark the exact location of the injection pump so that it can then be installed in its original position. On the pump flange and mounting bracket, apply the marks that must match again when reinstalling the injection pump;
Pic. 475. Bolts of fastening of the fuel pump of a high pressure on an arm
Pic. 476. In the place indicated by the arrow, there is a cone nut that secures the rear support of the injection pump
- guided by Fig. 475, unscrew the three bolts on the flange of the fuel injection pump and unscrew the separate bolt located on the rear support (pic. 476). Remove the injection pump.
The injection pump is not repairable. A faulty injection pump should either be replaced or sent for repair to a service station.
Installation procedure for injection pump:
- install the pump on the bracket, align it according to the marked marks and tighten the flare nut (pic. 476).
- check that all previously applied marks match and tighten the fastening bolts evenly in a circle with a torque of 25 Nm;
- check if the wedge is on the injection pump shaft, and carefully slide the gear wheel onto the shaft. Tighten the nut with a tightening torque of 55 Nm;
- tighten the union nuts of the fuel lines to a torque of 25 Nm;
- turn the injection pump gear so that the marks on the gear and the bracket match. Fix the gear wheel of the injection pump in this position by inserting the retainer 2064;
Pic. 477. Details of the toothed belt protection (in the place indicated by the arrow, install a mandrel to remove the camshaft gear): 1 - bolt, 10 Nm; 2 - back cover; 3 - upper protection of the drive belt; 4 - lower protection of the drive belt; 5 - bolt, 10 Nm; 6 - bolt, 20 Nm
- Loosen the camshaft sprocket bolt half a turn and tap the sprocket with a plastic or rubber mallet. Can insert a mandrel (pic. 477) and hit it with a plastic or rubber mallet. The camshaft gear will also be shifted;
- check if the engine is at TDC;
- Install the toothed belt as described in 17.4.2. Carry out all other work described in this section. Tension the V-ribbed belt and the power steering drive belt.
- check the moment of injection at the service station.
Injection timing adjustment
The injection timing should be checked and, if necessary, adjusted after the injection pump has been installed. As already mentioned, such an adjustment should be carried out at the service station.
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