Removing high pressure pipes

  • Remove the bolt (12) securing the high pressure pipe bracket
  • Unscrew the union nuts of the high pressure pipes from the fuel pump, rail and cylinder head

Remove the high pressure pipes of the inlet rail (13) (650.1111673), the rear high pressure pipes assembly (14) (650.1112463) and the front high pressure pipes assembly (15) (650.1112433).

Removing YaMZ-650 high pressure pipes

Close the holes to prevent dirt and dust from entering the nozzle nozzles.

This tubing kit is a non-removable assembly. In no case should you make any changes to the tube bundle, just as you should not change the flange fixation and the location of the tubes.

Removing the low pressure pipes

Removing YaMZ-650 low pressure pipes

  • Unscrew the nuts (3) and the nut (4) securing the low pressure pipes.
  • Unscrew the union nuts (2) of the low pressure pipes from the rail tee, the fuel pump and the fuel pressure and temperature sensor housing.
  • Remove the low pressure pipes (1) (650.1104390 - fuel outlet pipe, 650.1104525 - pipes from the fuel pump to the fuel filter assembly)

Removing the fuel pump

Removing the YaMZ-650 fuel pump

1. Disconnect the connector (1) of the fuel pump camshaft speed sensor (phase sensor) and the connector (2) of the bypass valve.

Fuel pump removal tool YaMZ-650

2. Using tool 1380, set the third cylinder to top dead center.

In this position, the fuel pump shaft key is turned up.

Fuel pump removal tool YaMZ-650

(When removing the fuel pump with the front cover installed, be sure to set the third cylinder to the top dead center position so that the key does not fall into the oil crankcase, and use tool 2547 to avoid shifting the gear).

  • 3. Remove the nut (650.1111662) securing the fuel pump gear, turn it over and fasten it to the gear with the reverse side.
  • 4. Using an M14 screw, with a screw part 60 mm long, remove the gear from the fuel pump by screwing it into the nut.
  • 5. Unscrew the four nuts (3) (311422) securing the fuel pump.
  • 6. Remove fuel pump (650.1111005).
  • 7. Place all parts in an impervious plastic bag.

Disassembly of the fuel pump

Removing the YaMZ-650 fuel priming pumpRemoving the YaMZ-650 fuel priming pump

  • 1. Loosen the screws (1).
  • 2. Press the fuel priming pump (2) with a plastic hammer (3).

Removing the YaMZ-650 fuel priming pump

  • 3. Remove the fuel priming pump (2).
  • 4. Remove the fuel pump gasket.

Removing the YaMZ-650 fuel pump phase sensor

  • 5. Loosen the bolt (1) (see Fig. a)
  • 6. Remove the phase sensor (2) (see Fig. 6).
  • 7. Remove the phase sensor gasket (3)

Fuel pump assembly

Installing the YaMZ-650 fuel priming pump

  • 1. Replace the seal (1) (see Fig. 1).
  • 2. Lubricate the seal (1) with engine oil.
  • 3. Center the fuel pump in relation to the fuel pump.
  • 4. Tighten the fuel priming pump mounting bolts in a checkerboard pattern to the recommended torque (see table).

Installation control of the YaMZ-650 phase sensor

  • 5. Lubricate the seal under the sensor with engine oil. Calculation of the thickness of the gasket required to ensure the gap “A” = 0.3 ± 0.1 mm (see Fig. 2):
  • - measure the value of “a”, corresponding to the length of the sensor;
  • - measure the value “b”, corresponding to the distance from the sensor support surface to the target of the fuel pump. The thickness of the sensor gasket is 0.3 + “a” - “b” mm.
  • 6. Install phase sensor.
  • 7. Screw on the phase sensor mounting bolt and tighten to the recommended torque (see Table 1).

Removing the high pressure rail

Removing the YaMZ-650 ramp

  • 1. Disconnect connector (1) from rail pressure sensor.
  • 2. Unscrew the union nut of the fuel drain pipe from the head.
  • 3. Unscrew the nuts (2) (311421) securing the ramp.
  • 4. Remove bracket (3) (650.1112556) for low pressure pipes and bracket bushings (650.1112554).
  • 5. Remove the rail assembly with pressure sensor and bypass valve (650.1112552) and rail bushings (650.1112550)

High pressure rail dismantling

Removing the YaMZ-650 pressure sensor

  • 1. Unscrew the rail pressure sensor (1) while holding the bushing (2).
  • 2. Plug the holes.
  • 3. After removal, place all parts in an impervious plastic bag.

High pressure rail assembly

  • 1. When installing, proceed in the reverse order of removal.
  • 2. Tighten the rail pressure sensor to the recommended torque (see table)

Installing the rail and high pressure pipes

  • 1. Install the high pressure rail in the reverse order of removal.
  • 2. Install the high-pressure pipes, joining their tips with fittings on the injection pump and the fuel rail, screw on the union nuts of the pipes.
  • 3. Install the rear and front high-pressure pipes as an assembly, for which manually install the pipe tips into the corresponding paired holes of the injector fittings and fuel rail fittings, screw on the union nuts. (On new parts, remove the transport plugs just before installing them).
  • 4. Final tighten the high pressure pipes in the following order:
  • - tighten the union nuts on the nozzles for supplying fuel to the injector with a torque Mcr = 15 ± 1.5 Nm and tighten by an angle of 60˚ ± 5˚;
  • - tighten the union nuts on the ramp with a torque of Mcr = 25 ± 2.5 Nm and tighten by an angle of 60˚ + 5˚;
  • - tighten 2 nuts for fastening the ramp and the bolt for fastening the bracket for high-pressure pipes with a front torque Mcr = 20 ± 4 Nm;
  • - tighten the pipe nuts on the fuel pump with Mcr = 15 ± 1.5 Nm and tighten by an angle of 60˚ ± 5˚.
  • 5. Tighten the union nut of the fuel drain pipe from the head to a torque Mcr = 28 ± 2 Nm.

Tightening torques of the YaMZ-650 fuel injection system

  • Fuel pump mounting studs - (sealant Loctite 542) 20±4 Nm
  • Bolts for fastening the booster pump - (tighten in a checkerboard pattern) 8±1 Nm
  • Bolt for fastening the fuel pump shaft speed sensor (phase sensor) 8±1 Nm
  • Screws for fastening the pressure and air temperature sensor in the intake manifold 6.5±1.5 Nm
  • Nuts for fastening the fuel lines to the rail and injector fitting - 40 Nm (in case of fuel leakage, tighten to a maximum torque of 50 Nm)
  • Rail pressure sensor 20±2 Nm
  • Sleeve for connecting the pressure sensor to the rail 45±5 Nm
  • Nuts for fixing low pressure polyamide pipes 28±2 Nm
  • Fuel pump oil filler plug 35±5 Nm
  • Engine sensor wiring harness screws 30±6 Nm
  • Injector nozzle nut in cylinder head - pre-tightening torque 5 Nm; final tightening torque 60 Nm
  • Fuel pump drive gear nut 195±20 Nm
  • Fuel pump mounting nuts - (tighten with a cross and then tighten only the nut that was tightened first) - 60 ± 12 Nm