Table of contents: 3.0L 1st generation engines (BUG/BUN) ↓ 3.0L 1st generation engines… ↓ 4.2L BTR Engine ↓ 4.2L CCFA and CCFC engine ↓
Caution: After disconnecting the fuel lines, plug the exposed openings to prevent dirt from entering the fuel supply system.
3.0L 1st generation engines (BUG/BUN)
1. The fuel injection pump installation details are shown in the illustration.
9.1. Installation details of the fuel injection pump for BUG/BUN engines:
1 - Damping weight;
2 - Nut, 70 Nm;
3 - Fuel injection pump gear;
4, 14, 15, 17 - Bolt, 22 Nm;
5 - Fuel injection pump;
6, 11, 13 - Gaskets, subject to replacement;
7, 10 - Hollow bolt, 25 Nm;
8 - Fuel supply line;
9 - High-pressure fuel pipe with union nut, 25 Nm;
12 - Return fuel line;
16 - Fuel injection pump bracket;
18 - Front fuel injection pump bracket;
19 - Bolt, 9 Nm.
2. Remove the upper engine cover (see Section 19 of Chapter 1).
3. Remove the union nuts (1 in illustration 13.35 Chapter 2) and remove the high-pressure fuel lines.
4. Remove the upper part of the intake manifold (see Section 4) and the fuel injection pump drive belt (see Section 8).
5. Give the nut (1 in the illustration), holding the injection pump shaft from turning, and remove the damping weight.
9.5. Damping weight nut.
6. Remove the fuel injection pump gear (see illustration 11.8 Chapter 2).
7. Disconnect the fuel supply line from the high-pressure fuel pump (2 in illustration 11.12 of Chapter 2) and the return fuel line (1), move them to the side.
8. Remove the bolts (1-4 in the illustration).
9.8. Fuel injection pump bolts.
9. Remove the bolts (1 and 3 in the illustration), disconnect the connector (2), carefully pull the belt cover in the direction of the arrow and pull out the fuel injection pump.
9.9. Bolts and fuel injection pump connector.
10. Installation is carried out in reverse order. After installing the fuel injection pump, bleed the fuel system (see Section 14).
3.0L 1st generation engines (CASA/CASB) and 3.0L SCR (SATA, SSMA)
11. The fuel injection pump installation details are shown in the illustration.
9.11. Installation details of the injection pump for CASA/CASB, CATA and CCMA engines:
1 - Bolt M6 (9 Nm) or M8 (23 Nm);
2 - Front fuel injection pump bracket;
3 - Bolt, 9 Nm;
4 - Protective plate;
5, 11 - High-pressure fuel line union nut;
6 - Fuel injection pump;
7, 10 - Hose clamp;
8 - Fuel supply line;
9 - Return fuel line;
12 - Bolt, 23 Nm.
12. Remove the upper part of the intake manifold (see section 4) and the fuel injection pump drive belt (see Section 8).
13. Remove the bolts (arrows in illustration 11.34 Chapter 2) and remove the fuel injection pump protective plate. Unscrew the union nuts (1-4) and move the high-pressure fuel lines to the side.
14. Disconnect the connector (3 in the illustration), remove the supply and return fuel hoses (1 and 2), unscrew the bolts (arrows) and remove the fuel injection pump.
9.14. Fuel injection pump connector and fasteners.
15. Installation is carried out in reverse order. Before starting the engine for the first time, the THVD should be filled with fuel (see Section 14). After replacing the high-pressure fuel pump or the pressure control valve "N276", adaptation should be carried out using a diagnostic tool.
Engines 3.0 l 2nd generation
16. The fuel injection pump installation details are shown in the illustration.
9.16. Installation details of the fuel injection pump for 3.0 l 2nd generation engines:
1 - Nut, 70 Nm;
2 - Adapter for the fuel injection pump sprocket, transfer to the new fuel injection pump when replacing;
3, 8 - Sealing ring, subject to replacement;
4 - Fuel injection pump;
5, 10 - High pressure fuel line, 25 Nm;
6 - Fuel supply hose;
7 - Return fuel hose;
9 - Fuel temperature sensor "G81", 2 Nm;
11 - Bolt, 22 Nm.
17. Remove the turbocharger (see Section 5).
18. Remove the oil cooler and coolant shut-off valve (see Chapter 3).
19. Remove the bolts (arrows in the illustration) and tilt the turbocharger connection (2) to the side.
9.19. Turbocharger connecting bolts.
20. Remove the rear sound insulation panel under the engine compartment (see Section 19 of Chapter 1).
21. Turn the crankshaft to TDC as indicated in paragraph 73 of Section 4 of Chapter 2. In this case, the mark on the crankshaft pulley should be in the 12 o'clock position (see illustration 29.22 Chapter 2).
22. Unscrew the service hole plug in the upper section of the oil pan and screw in locking pin No. 3242 with a force of 20 Nm (see illustration).
9.22. Fixing the crankshaft at TDC.
If necessary, rotate the crankshaft slightly back and forth until the locking pin fits evenly into the hole in the shaft and locks it.
23. Lock the fuel injection pump sprocket with the T40245 locking pin (see illustration 30.3 Chapter 2).
24. Unscrew the union nuts (arrows in illustration 31.27 Chapter 2) and remove the fuel pressure pipe (1) on the right side.
25. Unscrew the union nuts (arrows in illustration 31.25 of Chapter 2) and remove the fuel pressure pipe (1) on the left side. Seal any open holes to prevent dirt from getting in.
26. Disconnect the connector (2 in the illustration), loosen the clamps (3 and 4) and disconnect the fuel hoses.
9.26. Connecting fuel hoses to the high-pressure fuel pump.
27. Remove the bolts (see illustration) and remove the fuel injection pump.
9.27. Fuel injection pump bolts.
28. When replacing the high-pressure fuel pump, use new pressure pipes and also transfer the adapter to the new high-pressure fuel pump. To remove the adapter, remove the nut (arrow in the illustration), holding it from turning with the T40248 device.
9.28. Removing the adapter.
29. Installation is carried out in reverse order. Before starting the engine for the first time, the fuel injection pump should be filled with fuel (see Section 14). After replacing the high-pressure fuel pump or the pressure control valve "N276", adaptation should be carried out using a diagnostic tool.
4.2L BTR Engine
30. The fuel injection pump installation details are shown in the illustration.
9.30. Details of the installation of the fuel injection pump of the BTR engine:
1, 4, 13 - Bolt, 22 Nm;
2 - Nut, 70 Nm;
3 - Fuel injection pump gear;
5, 8, 11 - Gasket, subject to replacement;
6 - Fuel supply hose;
7, 9 - Hollow bolt, 25 Nm;
10 - Fuel return hose;
12 - High pressure fuel pipe, 25 Nm;
14 - Bolt, 9 Nm;
15 - Fuel injection pump bracket;
16 - Fuel injection pump;
17 - Front fuel injection pump bracket;
18 - Centering sleeve, 2 pcs.
31. Remove the fuel injection pump belt (see Section 8) and activator No. 2 "V339" EGR (see Part B).
32. Remove the union nuts (1 and 3 in illustration 4.47), unscrew the bolt (2) and remove the fuel pressure pipe. Remove the hollow bolts (4 and 5) and move the hoses to the side.
33. Disconnect the connector (3 in the illustration), unscrew the bolts (1 and 2), loosen the bolt (4) and remove the fuel injection pump.
9.33. Fuel injection pump connector and bolts.
34. Installation is carried out in reverse order. Before starting the engine for the first time, the high-pressure fuel pump should be filled with fuel and the fuel supply system should be bled (see Section 14).
4.2L CCFA and CCFC engine
35. The fuel injection pump installation details are shown in the illustration.
9.35. Details of the installation of the fuel injection pump of the BTR engine:
1 - Nut, 70 Nm;
2 - Fuel injection pump gear;
3, 12 - Bolt, 22 Nm;
4 - Fuel injection pump bracket;
5 - Bracket;
6 - Bolt, 9 Nm;
7, 11 - High pressure fuel pipe;
8 - Fuel supply hose;
9 - Fuel return hose;
10 - Fuel injection pump.
36. Remove the fuel injection pump belt (see section 8) and activator No. 2 "V339" EGR (see Part B).
37. Disconnect the connector (see illustration) and remove EGR pressure sensor No. 2 "G692".
9.37. Sensor connector "G692".
38. Loosen the union nuts (arrows in the illustration) and remove the pressure pipe.
9.38. Union nuts (arrows) of the pressure pipe.
Seal any open holes to prevent dirt from getting in.
39. Loosen the union nuts (arrows in the illustration), unscrew the bolt (1) and remove the pressure pipe.
9.39. Union nuts (arrows) and bolt (1) of the pressure pipe.
Seal any open holes to prevent dirt from getting in.
40. Disconnect the connector (1 in the illustration) Fuel injection pump, loosen the clamps (arrows) and disconnect the hoses.
9.40. Connector and hoses on the fuel injection pump.
41. Remove the bolts (see illustration) and remove the fuel injection pump.
9.41. Fuel injection pump fasteners.
42. Installation is carried out in reverse order. Before starting the engine for the first time, the fuel injection pump should be filled with fuel (see Section 14).