Installation of high-pressure fuel pump, injectors, high-pressure and low-pressure pipes ZIL-5301
The high-pressure fuel pump mating plate must be clean; nicks and other damage to the plate are not allowed
The fuel pump gasket must not have any visible damage
When installing the fuel pump, it is necessary to align the marks on the fuel pump drive gear and the splined flange.
The splined flange of the fuel pump gear must fit freely, without jamming, on the splines of the fuel pump shaft bushing.
The bolts securing the flange of the fuel pump gear must be tightened to a torque of 18-25 Nm.
When installing the fuel pump, it is necessary to check the fuel injection advance angle.
This is done in the following sequence:
- set the regulator control lever to the position corresponding to the maximum fuel supply.
Disconnect the high-pressure tube from the first section fitting and connect the torque scope instead (Fig. 1).
Turn the diesel crankshaft clockwise with a wrench until fuel without air bubbles appears from the glass tube of the torque scope.
Remove some of the fuel from the glass tube by shaking it.
Turn the crankshaft counterclockwise by 30-40°.
Slowly rotate the crankshaft diesel clockwise, monitor the fuel level in the tube, when the fuel starts to rise, stop turning the crankshaft.
If the retainer does not match the hole in the flywheel, adjust it as follows:
- - remove the hatch cover;
- - unscrew bolts 1, 2 and 3 and loosen bolt 3 by ½-1 turn (do not unscrew the bolt);
- - align the pin of the lock 2 with the hole in the flywheel, turning the diesel crankshaft in one direction or another;
- - using a wrench, turn the fuel pump shaft and splined flange by the nut until the fuel starts to rise in glass tube 1 of the torque scope;
- - install bolts 1, 2 and 3 in matching holes, trying to arrange them as evenly as possible around the circumference;
- - first tighten bolt 3, then bolts 1 and 2;
- - install the high-pressure tube in place and remove the retainer rod from the hole in the flywheel;
- - install the hatch cover in place.
The alignment of the splines of the fuel pump bushing and the splined flange when installing on a diesel engine is ensured by turning the diesel engine crankshaft or the pump camshaft.
Injectors of the same group must be installed on a diesel engine.
The sealing gaskets on the side adjacent to the injectors must be lubricated with US-1 GOST 33-51 solid oil.
The injector mounting bolts must be tightened to a torque of 20-25 Nm.
The high-pressure pipes must be secured at a distance of 10-15 mm from the union nuts with clamps and gaskets.
The low-pressure fuel pipes must be blown out before installing on a diesel engine compressed air.