The high-pressure fuel pump (Fig. 1 and 2), complete with injection advance clutch and fuel priming pump, is located in the collapse of the cylinder block and is fixed to the block with four bolts.
The drive of the pump from the distribution gears is carried out by the driven and leading coupling halves.
The rotation of the pump on the drive side is right (clockwise).
During the operation of the car, periodically remove the high-pressure fuel pump from the engine for inspection and adjustment on the stand.
To remove the high pressure fuel pump from the engine, remove the air filter cover, unscrew the rod and remove the filter element.
Loosen the clamps on the nozzles of the air filter housing and remove it.
Unscrew the fuel line bolts and disconnect the fuel hoses from the solenoid valve.
Disconnect the wire to the solenoid valve at the plug.
Remove the four bolts and remove the intake manifold connecting pipe and its gaskets.
Close the holes in the intake manifolds with plywood or cardboard plugs.
Remove the union nuts connecting the high pressure pipes to the high pressure fuel pump and injectors. Loosen the bolts, remove the brackets and high pressure pipes.
Unscrew the fuel line bolts and disconnect the fuel rods and the oil supply pipe from the high pressure fuel pump and the booster pump.
Remove the bolts securing the oil drain pipe.
Remove the bolts and remove the high-pressure fuel pump assembly with injection advance clutch and pre-supply pump.
Disconnected tips of fuel hoses and tubes, as well as fittings, threaded holes at the pump and injectors, close with plugs or insulating tape.
Check and adjust the high pressure fuel pump on the stand together with the working set of injectors, which must be checked and adjusted beforehand.
After installing the pump on the stand, fill the pump cavity with engine oil to the level of the drain hole on the rear cover of the regulator (0.16 ÷ 0.20 l).
Pour oil into the pump through the hole in the cover, closed with a stopper.
For the duration of the test, install the oil drain pipe on the pump so that its second end is directed upwards, and remove the casing 24 (see Fig. 2) from both rows of sections.
When checking the high pressure fuel pump, check:
- - start of fuel supply by pump sections;
- - value and uniformity of fuel supply by pump sections;
- - frequency of rotation of the camshaft of the pump, corresponding to the start of shutdown and complete shutdown by the fuel rate regulator of the pump sections through the nozzles.
Check and adjust the start of fuel supply by sections on the stand in the following order
Install the high-pressure fuel pump on the stand and connect it to the drive through the driven coupling half of the automatic fuel injection advance clutch.
Unscrew the bypass valve 11 (see Fig. 1), in its place screw the plug M14 x 1.5 with a seal.
Check the tightness of the delivery valves 12 (Fig. 3).
To do this, supply filtered fuel at a pressure of 1.7-2.0 kgf / cm2.
Turn off the fuel supply, for which the lever 7 (Fig. 4) is moved to the rearmost position - until it stops in the bolt 8 (4 - seal).
Fuel leakage from fittings 15 (see Fig. 3) after 2 minutes after supply to the pump is not allowed.
In case of leakage, replace the pressure valve assembly with body 11.
Check and, if necessary, adjust the opening pressure of the discharge valves with the fuel supply turned off.
To do this, through the pipeline with a valve and a pressure gauge, bring filtered diesel fuel through the inlet fitting under a variable, gradually increasing pressure from 5 kgf/cm2 to 15 kgf/cm2
Measure the opening pressure of the valve according to the readings of the pressure gauge on the fuel supply pipeline at the pump fitting.
For the opening pressure of the discharge valve, consider the pressure measured at the moment the fuel starts to flow out of the nozzlea 15.
The opening pressure of the discharge valve must be within 9 ÷ 10 kgf/cm2.
If the opening pressure of the valve does not correspond to the specified one, adjust it with the thickness of the package of shims 16.
As the thickness of the washer package increases, the opening pressure of the discharge valve increases, and as the thickness of the washer package decreases, it decreases.
After adjusting the pressure, tighten the fitting (tightening torque 10-12 kgf / m).
When checking and adjusting the start of fuel supply in sections, install a momentoscope on the fitting of the eighth section of the high-pressure fuel pump (Fig. 5), connect the remaining fittings to the injectors.
Through the inlet of the high-pressure fuel pump, supply filtered diesel fuel at a pressure of 15-16 kgf / cm2.
Turn on the full fuel supply, for which the lever 2 (see Fig. 4) is moved to the rearmost position - until it stops in the bolt 1.
Open the tap, and fuel will flow into the A cavity (see Fig. 3) at a pressure of 15-16 kgf/cm2.
Slowly rotating clockwise (when viewed from the drive side) the camshaft of the pump by the injection advance clutch, ensure that the fuel pressure opens the delivery valve 12 and the fuel begins to flow out of the capillary tube of the momentoscope installed on the fitting of the eighth section of the pump.
Further rotation of the camshaft by the clutch to stop the flow of fuel from the momentoscope.
At the moment when the fuel leakage from the momentoscope stops during the test, the helical groove “B” overlaps the fuel access plunger from the cavity “A” to the delivery valve and the momentoscope.
The moment when the fuel leakage from the momentoscope stops when checking corresponds to the beginning of the displacement (supply) of fuel by the plunger from the space between the plunger and the discharge valve.
Therefore, it is necessary to catch with particular accuracy the moment when the fuel flow stops from the momentoscope and fix the angle at this moment using the stand limb.
This angle of rotation of the pump camshaft will be the start of fuel delivery by the eighth section of the high pressure fuel pump.
Check and, if necessary, adjust the start of fuel supply by the eighth section of the pump by selecting the heel of the pusher.
For a correctly adjusted fuel pump, the start of fuel delivery by the eighth section should be 42°30′ ± 30′ before the axis of symmetry of the cam profile.
At the moment the eighth section starts supplying fuel, the marks on the pump housing and the injection advance clutch must match.
Mount the momentoscope in the order of pump operation to the fittings of the remaining sections.
Continuing to rotate the camshaft by the fuel injection advance clutch in the manner indicated above, determine the moments of the transformation of the fuel leak from the momentoscope by the remaining sections of the pump, while recording the readings of the dial on the stand.
These readings will be the moments when each section of the fuel pump begins to supply fuel according to the angle of rotation of the camshaft.
If the angle of rotation of the camshaft of the pump, at which the fuel supply by the eighth section began, is conventionally taken as the reference point - 0˚, then the remaining sections in the order of operation of the pump should start supplying fuel at the angles of rotation of the camshaft indicated in Table. 1.
The inaccuracy of the start of fuel supply by any section of the pump relative to the eighth section is allowed no more than ± 0˚20′.
Regulate the start of the fuel supply by installing the pusher heel of the desired thickness in the pusher under the plunger. When installing a heel of a thicker heel, the fuel starts to be supplied earlier, when a heel of a thinner thickness is installed, later.
A change in the anvil thickness by 0.05 mm corresponds to a change in the angle of rotation of the camshaft by 0°12′.
The manufacturer provides for the manufacture of the heel of the pusher of nineteen size groups (Table 2).
|
Designation dimensional groups |
Thickness heels pusher, mm |
Designation dimensional groups |
Thickness heels pusher, mm |
|---|---|---|---|
|
-9 |
3.60-0.05 |
1 |
4.10-0.05 |
|
-8 |
3.65-0.05 |
2 |
4.15-0.05 |
|
-7 |
3.70-0.05 |
3 |
4.20-0.05 |
|
-6 |
3.75-0.05 |
4 |
4.25-0.05 |
|
-5 |
3.80-0.05 |
5 |
4.30-0.05 |
|
-4 |
3.85-0.05 |
6 |
4.35-0.05 |
|
-3 |
3.90-0.05 |
7 |
4.40-0.05 |
|
-2 |
3.95-0.05 |
8 |
4.45-0.05 |
|
-1 |
4.00-0.05 |
9 |
4.50-0.05 |
|
0 |
4.05-0.05 |
The number of the size group is marked on the non-working part of the butt end of the pusher foot.
Check and adjust the pump in terms of the size and uniformity of the fuel supply by sections in the following sequence
Instead of the plug, install bypass valve 11 (see Fig. 1) and check the fuel pressure at the inlet to the fuel pump at a camshaft speed of 1300 rpm. Fuel pressure should be 0.6-0.8 kgf/cm2.
If the pressure differs from the specified, unscrew the valve plug and adjust with washers.
Diesel fuel must be filtered before being fed into the pump and have a temperature of 25-30 °C.
Turn on the full fuel supply, for which the lever 2 (see Fig. 4) is moved to the rearmost position until it stops in the bolt 1.
When the camshaft speed is 1300 ± 10 rpm, check and, if necessary, adjust the value of the average cyclic fuel supply by each pump section, which should be 75.0-77.5 mm / cycle.
The duration of each experiment in determining the volumetric fuel supply should ensure the volume of measured fuel in the burettes of the stand is at least 20 cm3.
The unevenness of the cyclic fuel supply across the pump sections should not exceed 5%.
The amount of cyclic flow of each section of the pump is regulated by turning the casing of section 17 (see Fig. 2) relative to the casing of the pump 1.
When turning the section body to the right, the cyclic feed decreases, when turning to the left it increases.
Before adjusting, loosen the high-pressure pipe nut by one or two turns, loosen nuts 19 and 22 by ½ turn.
After adjusting nuts 19 and 22, tighten (tightening torque 2.5—3.0 kgf/m).
Check and, if necessary, adjust with bolt 1 (see Fig. 4) the speed of the pump camshaft at the moment the rails start moving towards the fuel shutoff.
Before checking, unscrew the plug 13 of the rail (see Fig. 1). When checking, lever 2 (Fig. 4) must be pressed against bolt 1.
The racks should start moving at a camshaft speed of 1335-1355 rpm.
Check the speed of the camshaft corresponding to the complete shutdown of the fuel supply through the injectors by the speed controller when the lever 2 rests on the bolt 1.
Fuel supply at a camshaft speed of 1480-1555 rpm is not allowed.
Check and, if necessary, adjust the camshaft speed corresponding to the start of turning off the fuel supply through the injectors when lever 2 stops against bolt 3.
Complete shutdown of the supply should be at a frequency of rotation of the camshaft of the pump in the range of 300-350 rpm. Adjust with bolt 3.
If the fuel supply is cut off at a higher camshaft speed, unscrew bolt 3, tighten it at a lower speed.
Check and, if necessary, adjust the position of the bolt 8, which limits the travel of the lever 7 in the direction of turning off the feed.
When the lever 7 rests against the bolt 8, the fuel supply from the nozzles of all sections of the pump should completely stop at any pump speed.
At the same time, check the travel reserve of the rails in the direction of turning off the feed, which should be 0.7-1.0 mm.
Check and, if necessary, adjust the amount of starting fuel supply with bolt 6 at a camshaft speed of 100 ± 10 rpm and lever 2 rests against bolt 1.
The value of the average starting fuel supply should be 195-210 mm3/cycle. Adjust the amount of starting fuel supply with bolt 6; unscrew the bolt to increase the feed, tighten it to decrease it.
After performing inspection and adjustment work, seal the fuel pump in the places provided - to exclude the possibility of arbitrary changes in the adjustment.
In some cases, during the operation of the car, as well as when performing test adjustment work, it becomes necessary to partially or completely disassemble the high-pressure fuel pump to replace the heel of the pusher, pressure valve, plunger pair, etc.
Complete disassembly of the high pressure fuel pump:
install and secure the pump on a special stand or in a vice;
- - remove the seals, unscrew the four screws and remove the protective cover 24 (see Fig. 2);
- - remove the seal, unscrew eight bolts and remove cover 7 (see Fig. 1) as an assembly;
- - disassemble the centrifugal speed controller (Fig. 6), for which remove the axle 44 and, without disconnecting, remove the levers 42, 43 and 35, the thrust heel 47 with washers, the spring 37;
- - disconnect removed parts. To disconnect the levers 42 and 43 remove the bushing. In case of emergency, remove spring 39 and lever 36. Remove weight clutch 12 complete with bearing 11;
- - in case of bearing replacement, remove from retaining ring and press bearing 11 off the coupling. Remove plugs 13 (see Fig. 1);
- - unscrew the two nuts and remove the fuel priming pump 29 (see Fig. 2) with the spring 31 of the pusher and the manual fuel priming pump 25. If necessary, unscrew the bolt and remove the manual fuel priming pump;
- - unscrew the seven screws and, protecting the gasket from damage, remove the rear cover 1 (see Fig. 6) complete with bearing 4 and the low pressure pump pusher. Remove gasket 7;
- - open the clamps 34 on the rails, unscrew the two locking screws of the bushings and remove the bushings 9 (see Fig. 1), remove the right 33 (see Fig. 6) and left 38 rails. Unpin, remove washer and rack lever 41;
- - remove retaining ring 8 and weight holder 9 complete with bearing 23 and weights 13. If necessary, press axles 10, remove weights 13 and compress bearing 23;
- - remove the fuel pump sections as an assembly. To do this, mark the position of the sections relative to the socket in the pump housing - make a mark on the pump housing with a core and against the risks on the flange 23 (see Fig. 2) of the section housing.
This will help reassemble the sections to the position they were in before disassembly.
Unscrew nuts 19 and 22. In this case, it is necessary to rotate the camshaft so that the pusher and plunger of the section take the lower position when the nuts are unscrewed.
Otherwise, under the force of the pusher spring 8, the threads of the studs and nuts 19 and 22 may be damaged;
- - remove the lock washers of the fittings, remove the sections and pushers assemblies from the pump housing and arrange them in the cells of the portable rack. Screw nuts 19 and 22 by hand onto the studs of the pump casing;
- - unscrew the nut 15 (see Fig. 1), remove the washer 16 and press the coupling 14 from the camshaft with the I-801.16.000 puller, remove the key 17;
- - disassemble the drive of the speed controller, to do this, unpin and unscrew the nut 3, remove the washer and remove the gear 1 with the bearings 2 with a puller.
Unlock and unscrew nut 36, install puller I-801.26.000 (Fig. 7) and remove eccentric 34 (see Fig. 1), flange 32, gear 30 with crackers 31;
- - unscrew the screws securing the front 18 and rear 28 camshaft bearing caps, use two screwdrivers to remove the caps from the pump housing and remove the camshaft 25 assembly with bearings 23 and 27.
On the flanges of covers 18 and 28, for dismantling them with screwdrivers, two diametrically located grooves are made;
- - install the I-801 .29.000 puller (Fig. 8) and remove the bearings from the camshaft;
- - install puller I-801.24.000 (Fig. 9) and remove bearing 5 from cover 4 (see Fig. 1);
- - unscrew the locking screw 33 (see Fig. 2), remove the pusher 32 as an assembly;
- - if necessary, disassemble the fuel pump section;
- - unscrew the fitting 15 (see Fig. 3), remove the spring stop 14 and the spring 13 together with the fitting.
Install the device I-801.21.000 (Fig. 10) and, pressing the handle of the device, remove the body 11 (see Fig. 3), gasket 20 and pressure valve 12;
- - compress spring 5, remove plate 4, spring 5 and washer 6. Remove plunger pair assembly from housing 9 of the pump section (plunger 7, plunger sleeve 10). Remove the rotary sleeve 24 from the body 9.
When disassembling the section, it is forbidden to take the working surfaces of the plunger pair with unprotected hands.
Assemble the fuel equipment in the reverse order of disassembly. When doing this, keep the following in mind.
It is not allowed to depersonalize the assembled fuel pump sections and plunger pushers by the sockets of the fuel pump housing - they are matched to each other in terms of dimensional parameters.
Therefore, the sections of the fuel pump and the plunger pushers should be assembled, if possible, from previously used, fit, run-in parts and installed in the same slots in the fuel pump housing in which they were before disassembly.
The parts to be assembled must be clean, rubbing surfaces lubricated with engine oil. Corrosion, dirt, nicks on the working surfaces of parts are not allowed.
Prot is not allowed wipe the parts with a cleaning cloth and take them with bare hands.
New plunger sets or delivery valves should be flushed with filtered diesel fuel.
Before pressing the axles and dowel pins into the pump housing, it must be heated in an oil bath to 80 ÷ 100°C, and the parts to be pressed must be lubricated with engine oil.
Install rubber sealing rings into the grooves using mandrels without damage and twisting.
Before assembly, lubricate lead-in chamfers and surfaces of parts mating with sealing rings and cuffs with TsIATIM-20I or TsIATIM-203 lubricant.
When installing bearings after pressing the inner ring onto the shaft, check the condition of the inner ring.
Install the front cover 18 (see Fig. 1) carefully, protecting the cuff 20 from damage.
Tighten the cap screws 18 and 28 securely and lock them, tapping the body metal into the slot of the screw head.
When the cap screws 18 and 28 are tightened, the camshaft must turn freely by hand in the bearings.
Longitudinal (axial) play of the shaft when applying an axial force of 5-6 kgf should be in the range of 0.01-0.07 mm. Adjust with spacers 19.
When assembling the pushers of the plungers, press the pin flush with the supporting surface under the heel of the pusher.
The pusher roller must rotate freely on the sleeve, the sleeve on the roller axis. Jamming in the interface of the specified parts is not allowed.
The tappet and nut assembly, lubricated with engine oil, must move freely in the fuel pump seat under the action of gravity.
In case of replacement of the camshaft, fuel pump housing or plunger pushers, measure the sections of the fuel pump housing - dimension Н (Fig. 11).
When measuring, set the camshaft so that the plunger pusher of the section being measured takes its lowest position.
In case of replacement of the plunger pair, measure the “Н” dimension of the newly assembled section (see Fig. 3). Dimension “Н” is measured at the moment when the end of the plunger 7 closes the hole from the injection cavity “А”.
According to the results of measurements and tab. 3 determine the group number and clearly mark this number against the section socket on the fuel pump housing, flange 18 of the section housing. The previously standing group numbers should be minted.
|
Dimensions, mm |
No. groups |
|
|---|---|---|
|
Нк Fuel housings pump (see fig. 50) |
Нс Fuel sections pump (see fig. 42) |
|
|
117.80 – 117.85 |
110.70 – 110.75 |
0 |
|
117.85 – 117.90 |
110.75 – 110.80 |
1 |
|
117.90 - 117.95 |
110.80 – 110.85 |
2 |
|
117.95 – 118.00 |
110.85 – 110.90 |
3 |
|
118.00 – 118.05 |
110.90 – 110.95 |
4 |
|
118.05 – 118.10 |
110.95 – 111.00 |
5 |
|
118.10 – 118.15 |
111.00 – 111.05 |
6 |
|
118.15 – 118.20 |
111.05 – 111.10 |
7 |
|
118, 20 - 118.25 |
111.10 – 111.15 |
8 |
|
118.25 – 118.30 |
111.15 – 111.20 |
9 |
The difference between the group numbers of the section nest in the pump casing and section 1 assembly will determine the group number and the size of the foot of the pusher 3.
When assembling the fuel pump section with a new plunger pair, additionally check the ease of movement of the plunger along the entire stroke length and angle of rotation; jamming of the plunger in the sleeve is not allowed.
Check whether the plunger shank 7 is sunk into the plate 4.
The lower end of the plunger 7 should not reach the plane of the plate 4 by 0.1-0.3 mm.
When assembling, lubricate fitting 15 with diesel fuel and tighten (tightening torque 10-12 kgf / m).
After assembly, check the ease of rotation of the rotary sleeve 24 with the pusher spring 5 compressed. Seizing of the sleeve is not allowed.
Install the assembled sections into the fuel pump housing so that the section fastening studs are in the middle of the holes in the section housing flange.
In this case, the slots on the section housing for installing the rail and the mark on the plunger should face the cavity in the pump housing for the regulator.
Tighten nuts 19 and 22 (see Fig. 2) fastening flange 23 of the fuel pump section (tightening torque 2.5-4.5 kgf/m).
After tightening nuts 19 and 22, check that the rack moves smoothly when turning the camshaft.
After adjusting the start of fuel delivery by the pump sections, check the fuel pump for tightness of the low pressure fuel line according to the following procedure.
Drain the fuel from the low pressure line, plug the bypass valve hole with a plug.
Immerse the fuel pump in a bath of diesel fuel so that the threads of the fittings 21 are above the level of the fuel surface. Supply air through the fuel inlet to the low pressure fuel line.
The fuel system of the pump is sealed if, with a gradual increase in pressure at a rate of 1.5 kgf/cm2/min, from 0.5 kgf/cm2 to 5 kgf/ see2 no air bubbles are observed from the pump.
When assembling the regulator make sure that the gear 25 (see Fig. 6) on the cam shaft rotates without jamming.
After installing the damper parts (gear 25, cracker 26, spacer, key, flange 27 and eccentric 28), tighten nut 30 (tightening torque 4-6 kgf/m) and lock with washer 29.
Circumferential play in gear damper parts is not allowed.
The load of the regulator should differ in static moment by 2x10 kgf/m, no more. Weights mounted on the holder must swing freely on their axles under the action of their own weight.
Before pressing the bushing onto the coupling 12, heat the bushing in an oil bath to 80-100 °C, and lubricate the coupling with engine oil.
Should move and turn freely, without jamming and tacking:
- - coupler 12 in holder 9;
- - thrust heel in the coupling 12and on the finger 14 of the load clutch lever.
When assembling the levers 9 and 12 (Fig. 11), make sure that the adjusting bolt 16 of the regulator spring is screwed into the lever 9 to the size H = 52 ± 0.5 mm and locked with the nut 17.
Adjust the preload of the corrector spring with nut 14. It should be equal to 15-16 kgf.
After adjusting, lock nut 14 with a cotter pin. Screw the body of the corrector into lever 9 so that the head of the corrector protrudes beyond the “J” plane by 0.05—0.15 mm.
After installation, lock the corrector body with nut 13.
When assembling the top cover ensure the following
Before pressing the bushings, heat the cover to 80-100 ° C, and lubricate the bushings with engine oil.
The return spring 16 (see Fig. 6) must return the lever 7 (see Fig. 4) to its original position (until it stops against the bolt 6).
Turn the adjusting bolts for limiting the stroke of levers 2 and 7 into bosses and lock them with nuts.
Moreover, bolts 3 and 6 should protrude from the bosses by 2-4 and 8-10 mm, respectively, and bolts 1 and 8 should be wrapped flush with the ends of the bosses.
When assembling the cover 1 (see Fig. 6), before pressing the bearing 4, heat the cover to 80-100°C.
After pressing the cap, cool it down to 20 ± 3° С and measure the dimension “Е” (see Fig. 12) from the mating plane “А” of the cap to the end of the clip bearing.
When installing parts in the injection pump housing, ensure the following.
The governor levers should move freely without binding, and the bearing circlips should be in their grooves.
Set the regulator springs 37 (see fig. 6) and the starting feed 39 so that the free end of the spring hook is directed down to the camshaft.
The protrusion of the end of the bolt head 5 (see Fig. 12) from the mating plane "B" of the pump housing should be equal to the dimension C = (55.5 ± 0.2 mm).
The gap between the fuel pump body 3 and restrictive nut 4 must be equal to the dimension F = (0.8—1.0 mm).
Adjusting bolt 5 and limit nut 4 must be locked.
Before installing the lever 35 (see Fig. 4), check the force of moving the lever 43 connected to the rails by the pin 32 in the direction of the axis of the weight coupling.
With a stationary camshaft, this force should be no more than 0.15 kgf in the middle position of the racks, and 0.6 kgf in the extreme positions.
When installing the parts of the regulator in the housing of the high-pressure fuel pump, determine the thickness E) of the shim pack 18 (see Fig. 12).
The thickness of the shim package 18 affects the travel reserve of the rails in the direction of turning off the fuel supply with the regulator weights fully divorced, the camshaft speed of 500-550 rpm and the stop of the lever 2 (see Fig. 4) in the bolt 3.
Reducing the thickness of the shim package increases the travel reserve of the rails, increasing it decreases.
To perform this work, load clutch 7 (see Fig. 12), holder 6, complete with weights, move in the axial direction towards the rear cover 1.
In the resulting gap between the clutch 7 and the fifth 11, install a gauge-device with a thickness of 3.75-0.026 mm.
After installing the gauge-device, rest the lever 9 against the head of the bolt 5, the lever 12 against the lever 9; at the same time, move the holder 6 with the clutch 7 to the heel 11 so that they are clamped:
- - gauge-device between clutch 7 and fifth 11;
- - load rollers between holder platform 6 and coupling 7. With holder 6 in this position, measure the dimension G - protrusion of the end of the holder beyond the mating plane "В" of the pump housing.
Use the formula to determine the thickness D of the shim pack 18:
B = E +0.6 - G
In this formula, the dimensions E and G were determined by measurements, 0.6 is the thickness of the paronite gasket 2.
It is also possible to determine the thickness of D of the shim pack if you have a 3.75-0.025 mm gauge and a set of feeler gauges.
At the same time, install and fix the back cover 1 with the gasket 2 on the pump casing 3 and fasten it with screws. Move the holder 6 with the coupling 7 to the cover 1 until the end of the holder stops against the bearing of the cover.
Press the lever 9 to the head of the bolt 5, the lever 12 to the lever 9 and install the gauge - fixture and a package of probes into the resulting gap between the heel 11 and the clutch 7.
The thickness of the stylus pack must be such that the weight rollers are clamped between the weight holder platform and the weight sleeve.
The thickness of the feeler gauges will determine the thickness of Е) gasket package 18. After completing the work, remove cover 1 and install gasket package 18 with Е thickness), check the locking of nuts 3 and 36 ( see Fig. 1).
Place the cover on the pump housing and fasten it with screws.
Install the three upper screws of the rear cover on the paste sealant. The difference between the determined thickness D of the gasket pack and the actually installed thickness should not exceed 0.1 mm.
After assembly, make sure that the travel reserve of the rails in the direction of turning off the supply is at least 0.5 mm with the regulator weights fully extended.
In the assembled regulator, all parts should move without jamming. The levers for controlling and turning off the supply of the regulator under the action of the springs must clearly return to their original position.
When assembling the low pressure fuel pump and manual priming pump, consider the following.
The stem and bushing of the low pressure fuel pump are a precision pair, which must not be dismantled.
If it is necessary to replace one of the parts, change them as a set. Install a new bushing with a stem into the body using epoxy glue. After the glue has dried, check the tightness of the housing with air under pressure of 4÷6 kgf/cm2.
The body and piston of the low-pressure fuel pump are divided into two size groups according to the size of the diameter, respectively, of the cylinder and piston, the cylinder and piston of the hand pump are divided into three size groups.
The group number is marked prominently on the parts. In case of replacement, the newly installed part must be of the same size group.
When assembling the low pressure fuel wear parts and the hand pump, lubricate (moisten) with filtered diesel fuel,
Tighten the threaded connection of the hand pump cylinder with the cylinder body and the bolt of the hand pump assembly to the low pressure pump body. The tightening torque must ensure the tightness of the connection.
When assembling the automatic fuel injection advance clutch, do not depersonalize the weights.
According to the static moment relative to the hole for the axis of the load, they are divided into six dimensional groups.
The difference in the static moment of loads of one group should be 8x10 kgf / m, no more.
Before assembling, lubricate the fuel injection advance clutch parts with engine oil.
Tighten the threaded connection of the housing 1 with the driven coupling half 9 (tightening torque 25-28 kgcm).
After assembling the high-pressure fuel pump assembly with the low-pressure pump and the injection advance clutch, run in bench conditions for an hour on diesel fuel with a camshaft speed of 1000 ± 50 rpm.
When running on the stand, the pump should be lubricated with forced circulation of filtered engine oil at a pressure of 1-7 kgf / cm2.
Before starting the tests, pour 0.16-0.20 l of engine oil into the pump through the hole closed with a plug 5 (see Fig. 4) and into the coupling through the holes closed with screws 13.
The fuel pressure in the low pressure line of the fuel pump should be 0.5-2 kgf/cm2.
For the first 10 minutes of running-in, lever 2 (see Fig. 4) should rest against bolt 3.
Over the next 50 minutes, lever 2 should move between bolts 1 and 3 at a frequency of 10-12 complete movements per minute.
Run in with a tested set of injectors.
During the running-in of the pump, knocks, extraneous noises are not allowed. The oil temperature at the outlet of the fuel pump must not exceed 80°C.
If a knock, extraneous noise or some other malfunction is noticed during the break-in, stop the break-in, disassemble the pump, eliminate the malfunction and assemble the pump.
Repeat the running-in of the pump in full if, when eliminating the malfunction, at least one of the following parts (assemblies) was replaced with a new, not run-in one: fuel pump housing, plunger pair, camshaft with bearings, plunger pusher, discharge valve, regulator drive gear , weight holder, thrust heel, regulator levers, regulator back cover, rail, housing or piston or low pressure fuel pump pusher.