Attention! The high-pressure fuel pump is not subject to repair or overhaul and, in the event of a malfunction, is replaced as a set with an identical one from the exchange fund of the workshop or with a new one.
To regulate the injection pump, as well as to remove and install it, special tools are required. The injection pump can only be adjusted in a workshop where the necessary equipment is available. In addition, experience is also required to adjust the injection pump. If the high pressure pump is removed on your own, it is recommended that you follow the instructions for replacing the toothed belt so that the high pressure pump can be released and removed.
Adjustment and removal of injection pump
Vehicles with XUD11BTE engine
1. Pinch the hose 1 of the power steering with the appropriate clamp [4], and then disconnect it (see illustration).
3.1 Pinch the hose 1 of the power steering with the appropriate clamp [4] and then disconnect it
2. Remove the reservoir 2 of the power steering and disconnect the wiring harness 3 (see illustration 3.1).
3. Disconnect and move aside pipeline 4, plugging its holes (see illustration 3.1)
4. Disconnect the wire «masses» (-) from the ABS control unit 5. and then move the unit to the side without disconnecting the plugs from it (see illustration 3.1).
5. Disconnect the supply air duct from the intake manifold (see illustration 3.1).
6. Turn bolt 7 ¼ turn and then unscrew bolt 8 and remove cover 9 (see illustration).
3.6 Turn bolt 7 ¼ turn and then unscrew bolt 8 and remove cover 9
7. Remove the front right wheel and fender liner.
8. Turn the crankshaft along the engine and align the hole on the camshaft gear into which the thrust roller is inserted with the hole on the rear timing cover.
9. Insert the thrust roller [1] into the appropriate hole and lock the crankshaft (see illustration).
3.9 Insert the thrust roller [1] into the appropriate hole and lock the crankshaft
10. Remove the intake manifold 10. Plug the opening of the branch pipe on the manifold, to which the supply air duct is attached, with a clean rag (see illustration).
3.10 Remove intake manifold 10
11. Unscrew the bolts 11 of the injection pump and disconnect the high pressure fuel lines from the injection pump and fuel injectors by unscrewing the union nuts (see illustration 3.10).
12. Turn the high pressure fuel pump until it stops in the direction of the fuel supply delay and unscrew the plug 13 (see illustration 3.10).
13. Insert the appropriate thrust roller [3] into the hole where plug 13 was located (see illustration).
3.13 Insert the appropriate thrust roller [3] into the hole where plug 13 was located
14. Slowly rotate the injection pump in the direction of fuel injection advance (to the bulkhead of the engine compartment), while holding the thrust roller in the hole so that when aligned, it goes into recess A (see illustration).
3.14 Slowly rotate the injection pump in the direction of advancing fuel injection so that the thrust roller, when aligned, enters groove A
15. Holding the injection pump in this position, tighten the bolts 11 and union nuts of the high pressure fuel lines with a force of 20 Nm.
16. Remove thrust rollers 1 and 3, which locked the crankshaft and high pressure fuel pump.
17. Turn the crankshaft along the engine and again align the hole on the camshaft gear under the thrust roller with the corresponding hole on the rear cover of the gas distribution mechanism.
18. Lock the injection pump with thrust roller 3, slowly turning the crankshaft. until the roller enters recess A (see illustration 3.14).
19. Make sure that the injection pump is adjusted correctly by inserting the thrust roller 1 and locking the crankshaft (see illustration 3.9). If the injection pump is adjusted correctly, then the thrust roller should go into the corresponding holes without problems. Otherwise, the injection pump adjustment procedure should be repeated.
Vehicles with DK5ATE engine
20. Partially remove the toothed belt and disconnect plugs 1 and 4 (see illustration),
3.20 Partially remove the toothed belt and disconnect plugs 1 and 4
21. Disconnect the plugs from the injection pump, remove the bracket 3 and disconnect the return and supply fuel lines (see illustration 3.20). The tightening torque of the bracket bolts is 25 Nm.
22. Unscrew the bolts 5 and remove the injection pump (see illustration). Bolt tightening torque 20 Nm.
3.22 Unscrew the bolts 5 and remove the injection pump
The injection pump is installed in the reverse order of removal.
Checking the adjustment of the injection pump
23. Insert the thrust roller [1] (see illustration 3.22). If the roller is installed without problems, then the injection pump is adjusted correctly.