- a) Special locking device for camshaft pulley and fuel pump drive gear Mot. 854
- b) Special puller for fuel pump drive gear Mot. 1053
- c) Micrometer holder and micrometer for adjusting injection timing Mot. 856.
- d) Crankshaft TDC setting pin Mot. 861. It can be replaced with a punch with a diameter of 8 mm.
2. Before removing the fuel pump mount and camshaft drive cover, perform the following work:
3. Disconnect the negative battery cable. Keep the radio code handy (if installed).
4. Remove the shield and the upper tube of the frame cross member.
5. Partially disconnect the radiator and tilt it to expose the camshaft drive cover.
6. Place the front of the vehicle on a lift and remove the power steering pump belt, alternator belt and water pump belt.
7. Disconnect the cable shield from the camshaft drive cover and remove the cover. This will release the fuel pump drive mechanism. Cover the generator with a thick layer of dense cloth to protect it from diesel fuel.
8. Disconnect the connections indicated by the arrows (see illustration). Both lower arrows show where the hose needs to be clamped. After applying the installation mark to the spring clamp (1), disconnect the throttle cable, remove the locking mechanism traction cable and the fast idle cable, disconnect the fuel lines from the high-pressure fuel pump and unscrew the injectors.
17.8 Remove the connections indicated by the arrows from the pump. The two lower arrows indicate the hose connections
9. Turn the engine over so that both sprockets (camshaft and fuel pump) installed as shown in illustrations 20.37 from Section 2. In the picture the toothed drive belt is removed, however the installation marks are clearly visible.
10. When performing temporary installations of the camshaft drive cover, it is necessary to see the installation marks through the inspection windows. Check the centering again from this position, turn the crankshaft back exactly three teeth of the drive belt. In this position, insert either the locking mechanisms into the engine (see illustration), or mark the position of the sprockets accurately so that they can be installed as before.
17.10 Insert a locking tool between both sprockets to prevent them from turning
11. Loosen the pump shaft nut and move it to the end of the shaft. If a locking mechanism is used, the motor will not be able to turn. Otherwise, insert a punch through one of the holes in the sprocket (into the cylinder head), to prevent the crankshaft from turning.
12. Using a puller, pull the drive gear off the pump (see illustration). Do not use a mallet to remove the gear. The jaws of the puller are installed in the holes of the gear, and do not cling to its teeth. Since the gear is made of brittle material, the teeth can easily break.
17.12 Special puller for fuel pump drive gear
13. Remove the protective cover under the fuel pump and the rear pump support. Then remove the remaining pump mounting bolts. Use an offset open-end wrench to remove the lower pump nut.
14. Carefully remove the pump. Make sure that the locking key does not fall out of the pump shaft. Install the pump as described above and adjust, provided that you have a micrometer. Make the adjustment very carefully.
15. To install the dial micrometer, screw in the plug (1) and push the micrometer into the sleeve (see illustration).
17.15 Assembly and installation of the micrometer with dial. The plug (1) must be unscrewed in advance
16. Screw two nuts onto the pump shaft threads and lock them together.
17. Loosen the contact screw (1) (see illustration), move the lever back a little and turn the fork head a quarter turn.
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17.17 Installing the fuel pump. The digital designations are described in the text
18. Turn the pump shaft in the direction indicated by the arrow in Illustration 17.17 (put the open-end wrench on the built-in nut "2") to find the piston BDC. In this position, push the micrometer approximately half the working stroke of the measuring finger and set it to "zero".
19. Turn the pump shaft further in the normal direction until the shaft keyway is in the same plane as the threaded connections of the fuel line of the first cylinder, as shown in Illustration 17.17. Unscrew both screwed nuts again.
20. Insert the key into the pump shaft and place the drive gear on the shaft. Install the pump in the prescribed position and secure with the nuts and washers of the mounting flange. Tighten the nut with your fingers.
21. Tighten the shaft nut to 50 Nm and remove the locking device shown in Illustration 17.10. If the locking mechanism is not used, lock the drive gear.
22. Turn the crankshaft in the normal direction and lock it in this position as shown in illustrations 20.33 from Section 2 (see also the description of the installation of the toothed drive belt). Illustration 17.22 shows where the crankshaft locking pin is installed in relation to the installed micrometer.
17.22 Micrometer with dial and locking pins (861) installed in the fuel pump and, accordingly, in the cylinder block
23. Loosen the fuel pump until the reading is 0.70 mm (±0.02 mm deviation is allowed). Tighten the pump fastening in this position.
24. Rotate the crankshaft one and 3/4 turns in the normal direction of travel (remove the locking pins in advance) and make sure the micrometer reads "zero" when the pump piston is at BDC. Then set the crankshaft back to TDC and push in the locking pins (see also illustration 17.22).
25. Check that the micrometer reads 0.68-0.72 mm and that the timing marks on the pump drive gear and on the camshaft sprocket are positioned as shown illustrations 20.37 from Section 2 or temporarily install the camshaft drive cover to view the timing marks through the inspection windows. Remove the micrometer from the back of the pump and screw in the plug with a new sealing gasket.
26. Press the cold engine starting device lever and lock the clamp in its original position if the lever is opposite the fork head.
27. Connect the rear support to the fuel pump and to the cylinder head. Tighten the fastener evenly.
28. Perform the remaining work in reverse order. Note the differences in the hollow bolts. The hollow bolt of the fuel outlet line has a channel of a certain diameter and a filter. This bolt is screwed into approximately the middle of the pump.
29. Adjustment of fast idle speed is carried out as described in next chapter.
30. To remove air from the fuel system, remove the union nuts of the high-pressure fuel lines from the pump. If the fuel comes out of the union nut threads without bubbles, the system does not contain air. Then tighten the union nuts to a tightening torque of 20 Nm.