Adjusting the fuel supply to the injection pump.

Fuel pump high pressure(TNVD) - a device that serves to supply a certain amount of fuel to the engine. This is a very important element of any engine. internal combustion. Therefore, it is necessary to figure out in a timely manner how to regulate it, that is, set up the correct fuel supply.

Otherwise, the engine may receive either an excess amount of fuel or a shortage. Sooner or later, this will lead to detrimental consequences that will force major repairs, which is an expensive process. In order to avoid breakdowns and provide the engine with the right amount of fuel, you need to learn how to properly regulate the supply to the high pressure fuel pump.

You can adjust the injection pump at a specialized station Maintenance, but it will take you a considerable amount of money. However, customization is also possible. At first glance it may seem complex process, but having a good understanding of all the features, you can quickly and cost-effectively configure fuel pump. So, let's take a closer look at the technique of increasing and decreasing feed. fuel mixture.

How to reduce feed?

If you notice that your car began to consume a large amount of fuel, as well as literally "choke" with an excessive intake of the fuel mixture, then the increased dose that the pump supplies to the vehicle's engine may have become a problem.

In order to prevent further damage to the engine, it is necessary to reduce the fuel supply to the engine in time. This is done by performing the following list of actions:

1. Stock up necessary tools
2. Adjust the air supply
3. Test

As often happens, with increased supply, the engine begins to emit an increased amount of gases, that is, they ate from exhaust pipe your vehicle is emitting excessive amounts of emissions, then all of the above measures should be taken.

First of all, stock up on the necessary tools. Their list includes those keys with which you need to adjust the fuel pump. For example, the key is at 13. After that, they also need to set the optimal level of air supply. This will allow air and gasoline to mix, thus forming an excellent fuel liquid. After adjustment, you need to start the engine and test. If still there is smoke, then tighten the air supply more, and if the smoke stops, then you can praise yourself, since the pump is set.

Before climbing into fuel system, it is highly recommended to consult a specialist who can give you a couple important tips. Applying his advice, it will be possible to avoid banal mistakes and save the engine from even more serious damage. After all, an ignorant person should not independently adjust the fuel pump.

How to increase supply?

Reduced fuel supply to the engine is an alternative problem. The main signs of insufficient supply are considered to be premature and spontaneous shutdown of the car, engine tripping, as well as reduced traction. More often, this problem arises among lovers of savings. That is, in order to save on fuel, owners often deliberately reduce the supply of gasoline (gas), which leads to these problems.

An increase in the supply through the high-pressure fuel pump is possible through the tightening of special screws that are located on top and on the side of the fuel supply device. By unscrewing these bolts, the gap for the passage of the fuel mixture increases, thereby normalizing the overall performance of the vehicle. More fuel will be able to pass through a larger hole diameter, and then the engine will be able to operate on full power.

Of course, due to the increase in flow, you do not need to twist it too much, as this can lead to excessive mixture flow into the motor and the previous problem. Before you start setting up, be sure to consult with a specialist, but rather do everything under the supervision of a professional.

Types of injection pumps and their adjustment.

Nowadays, there are two types of high pressure fuel pumps:
1. Mechanical
2. Electronic

Mechanical injection pump.

This type of device is more popular among older models. Vehicle. All adjustments, and directly the fuel supply itself, takes place in mechanical mode. Setting up such installations requires some knowledge, since incorrect adjustment can lead to more complex breakdowns.

Electronic injection pump.

This pump is installed in modern engines diesel type. The device is a more advanced and well-coordinated device that is able to extremely accurately distribute the fuel supply to the engine. A special ECU control unit monitors all processes of the electronic pump.

The output to the owner of data on the pump's performance is carried out as a result of the collection of information from all sensors that are located on the pump itself and nozzles. Self adjustment fuel supply in this type of pump is possible only if there is a specialized stand with the proper equipment. The adjustment must be carried out under the supervision of a specialist in his field, who will help you quickly understand the operation of the electronic high pressure pump.

The high pressure fuel pump is technically important element system that provides fuel injection to a diesel engine. The pump provides the supply of diesel fuel under necessary pressure and in the right amount. Simply put, the injection pump is responsible for providing the fuel system with fuel and its proper circulation.

Varieties of injection pump

High pressure fuel pumps are separated by the method of fuel injection. It can be produced by a battery injection system or using a plunger. The main element of the pump is such a part as a plunger pair, which visually represents a piston with a cylinder. Fuel is supplied inside the cylinder. Then it through inlet valve pushed out by the plunger. In various techniques, several structurally different pumps are used:

distributive. The design of the unit has one or a pair of plungers that pump fuel through the cylinders;

in-line. These pumps structurally have only one plunger;

trunk. This pump pumps fuel into the battery.

Any equipment, even imported and the most reliable, can fail. As a rule, the earlier a breakdown is detected, the more inexpensive means it can be solved. If the repair procedure is not performed immediately, then a failed pump element can affect the working mechanisms of the entire power unit, and this breakdown will lead to a major overhaul. Each manufacturer establishes a certain period of operation in the passport and, subject to the rules of operation and terms technical inspection major repairs may not be necessary. If we neglect the timing and the need for periodic inspection and operate the car even if a malfunction occurs, it will not reach the period recommended by the manufacturer and will require expensive overhaul.

The most common faults

Most often, the following malfunctions occur in TNVD:

mechanical pump. This malfunction is natural and occurs over time. More often, wear can occur when the car has been used with increased loads. Breakage manifests itself increased noise engine at start-up, uneven operation, inability to start it in a hot state and power reduction;

malfunction due to the use of fuel Low quality. Since the fuel is the lubricant for the pump, its purity is the basis for the long-term operation of the unit. The fuel must not contain impurities in the form of small mechanical particles, water or gasoline, as they cause the device to break down;

the manifestation of a malfunction of the high-pressure fuel pump may affect the electronics of the car. Devices start to work incorrectly or turn off spontaneously.

Repair of high-pressure fuel pumps is often carried out by preliminary disassembly of the unit with the replacement of worn parts. For disassembly and subsequent collection, you will need the minimum amount of tools that are available in the garage of any motorist. If there is no necessary knowledge on the application device, it is better to entrust the repair to car service specialists.

High pressure fuel pump adjustment

Periodically, each high-pressure fuel pump needs to carry out an adjustment procedure. It is quite possible to make it yourself if you have necessary equipment. Professional adjustment of the injection pump is carried out on special adjustment stands that private garages are not equipped with. First, the metered fuel injection advance clutch is removed from the high-pressure fuel pump, then the camshaft is coupled with the drive device, which is located on the stand. Next, the verification and adjustment process itself starts, which reflects the uniformity of the fuel supply, as well as the volume of fuel supplied. The moment of fuel supply is also determined. All indicators are compared with the reference ones and recorded. The process of adjusting the moment of fuel supply uses a special device - a momentoscope. In order to adjust the feed moment correctly, it is necessary to determine the place where the adjusting bolts screwed into the plunger pushers will be screwed.

As you can see, in order for the high-pressure fuel pump not to fail within the time strictly allotted by the manufacturer, it is the timely conduct of the adjustment procedure, as well as the quality of the fuel used. To ensure the proper quality of lubricants, it will be necessary to purchase oils recommended by the manufacturer, as well as timely replacement of the appropriate filters that control the purity of the oil. With knowledge of design features devices, it is quite possible to do all the work yourself, but carrying out these works by specialists will provide high quality activities, as well as tight deadlines. Also, such an approach will ensure the error-free activities, since the adjustment on their own will not provide the required accuracy.

Technology for assembling and adjusting a high pressure fuel pump (high pressure fuel pump) of a diesel engine

Assembly of diesel engine fuel equipment.

The fuel equipment of internal combustion engines includes units and mechanisms that ensure the cleaning and supply of fuel to the cylinders in an amount corresponding to the engine load at a given number of revolutions.
At carburetor engines fuel equipment includes booster pumps, filters and carburetors; diesel engines have booster pumps, filters, fuel pumps, injectors and pipelines.

Assembly is described below fuel equipment diesels.
For normal atomization, fuel is supplied to the nozzles at high pressure, reaching 800-1000 kg/cm2 in some diesel designs, which creates special requirements for the tightness of high-pressure pipeline connections.
Small gaps in the interface of such important nodes, How plunger pairs and atomizers, as well as small sections of atomizing holes require fine cleaning fuel, as even small solids in the fuel can cause parts to jam and clog holes.
To ensure even loading of all cylinders multi-cylinder engines uniform fuel supply by all injectors is required both at maximum and at partial loads.
To meet these requirements for fuel equipment, it is necessary to carefully carry out all assembly operations, maintain the gaps specified in the drawing, and exclude jamming in moving joints. In addition, cleanliness should be maintained in assembly halls and workplaces.

Assembly and adjustment of high pressure fuel pumps.

By design, fuel pumps of internal combustion engines can be divided into two main groups: single-plunger pumps installed on single-cylinder engines or on each cylinder of multi-cylinder engines, and multi-plunger (or block) pumps that supply fuel to all or part of the cylinders of a multi-cylinder engine.
In many engine designs, the speed controller is connected to the fuel pump in a single unit.
Fuel pumps mounted on engines different power, differ in size, but this does not significantly affect the technology of the assembly process.
In small-scale production, fuel pumps are assembled at a stationary assembly site. In large scale and mass production assembly of pump units is carried out at specially equipped workplaces, and the general assembly is carried out on a conveyor, where a certain operation is performed at each working position.

As an example, let's consider the technology of assembling a multi-plunger fuel pump of a block design (See Fig.) installed on the YaMZ 240 engine or its modifications.
Before assembly, all parts of the pump are thoroughly washed, blown dry compressed air, and then served in the assembly shop. Parts, the fit of which is ensured by selective selection, are supplied in containers, sorted into groups.
The assembly of nodes is carried out at workplaces installed along conveyors or in assembly shops - in small-scale production.
At the first cycle (the first working place), a plug and a fitting of the fuel supply channel, studs for the axle box and air bleed plugs are installed in the pump housing. Plunger pairs are placed in the housing at the second workplace, and they are fixed with locking screws. With the screws tightly tightened, the plunger sleeve should have a slight free movement along the axis. Check valves with sealing copper-fiber gaskets put on them with the help of a special sleeve are installed in the opening of the body on the end of the sleeve. Springs, plunger pairs and check valves fasten with fittings. The fitting is tightened with a torque wrench. After tightening the fittings, the plungers should rotate freely and move in the sleeves. The housing assembled with the pump elements is pressed with a clean diesel fuel at a pressure of 8 kg/cm2. Fuel leakage at the sleeve landing sites, threaded fittings and plugs is not allowed.
At the next stage, rotary bushings with gear rims are assembled. The position of the groove of the rotary sleeve relative to the middle tooth of the crown is provided by a special device.
When assembling the pusher, the bolts are selected so that the swing of the bolt in the pusher housing is minimal. The pusher roller is mounted on the axle on needles. For ease of assembly, a roller is placed in the roller, the length of which is slightly less than the length of the needles; 15 needles are placed in the gap between the walls of the roller and the roller; thrust washers are placed on the ends of the roller. In this form, the roller is placed in the body and then the auxiliary roller is pushed out by the axis of the pusher.
When assembling the camshaft, ball bearings are pressed onto the outer journals. When assembling the shafts of multi-plunger pumps with intermediate supports, sleeve bearings are put on the middle necks. Before installing the bearings, the necks are thoroughly wiped and lubricated with oil.

In the following operations, the base of the regulator and the axle box are assembled. The assembly consists in installing the seals and the regulator cross pin.
At those workplaces where the nodes for assembling the regulator are assembled, the regulator body is assembled. On the cover of the regulator, a spring guide bushing, a mechanism that allows you to change the compression of the spring, and a handle for changing the speed are mounted; they assemble the regulator core with weights and rollers, the regulator lever with a spring cup and a thrust bolt with a spherical head, and the regulator rail rod with a spring.
The installation operation of the rack and swivel sleeves must be carried out very carefully. The rail is installed in the bushings of the housing and is locked against rotation with a screw. The movement of the rack in the bushings must be smooth, without local jamming, which can disrupt the normal operation of the regulator.
Swivel sleeves with toothed rims are installed on the outer cylindrical surface of the plunger sleeve at the middle position of the rack; in this case, the axis passing through the cut of the ring gear must be perpendicular to the axis of the rack. The gap between the teeth of the crown and rack must be uniform. The gap is checked with the rail fixed, by changing freewheel crown, which, at a radius of 20 mm, should be within 0.05-0.20 mm. To check the gap, use an indicator device. The probe of the device rests on the crown; the amount of free play is counted by the indicator. The indicator device, fixed in the bracket, on the crawler, can move along the rod, which is attached to the feet of the pump housing with the help of brackets, screws and a split sleeve.
Then, the upper spring plate is installed in the recess of the housing, after which the spring is put in place. Pushers are placed in the holes of the body, the lower spring washer is put on the plunger head.

The camshaft is installed in the next position. In the end openings of the housing, the base of the regulator and the axle box are installed with gaskets, the sockets of which include ball bearings of the camshaft. The base of the regulator and the axle box are fixed with screws and nuts. To set the axial movement of the cam shaft between the box and ball bearing stack two adjusting washers of different thicknesses. The indicator checks the axial movement of the cam shaft, which should be equal to 0.2-0.4 mm. If it is larger, the axle box is removed and additional shims are installed. On the conical ends of the cam shaft, a cam clutch is installed, the gear of the regulator and fixed with nuts.
Then the gap between the ends of the plungers and the saddles of the discharge valves is adjusted, which should be equal to 0.4-1.0 mm. The gap is set at the maximum lift of the pusher with a cam.

At the next position, the regulator is assembled. A core with weights is put on the finger and the gap between the teeth of the regulator drive gear and the core is checked. The gap should be within 0.15-0.3 mm at all positions of the camshaft. A rod with a spring is placed on the protruding end of the rail, and a regulator sleeve is placed in the hole of the cross pin. Then, the regulator body with a lever is attached to the base of the regulator; there must be a gasket between the base and the body. The rack rod is connected to the lever. A regulator cover with a speed adjustment mechanism is attached to the end plane of the regulator housing with screws. Before fixing the lid, the main spring of the regulator is installed in the sleeve fixed on the lid and the glass.

At the last position of the conveyor, a booster pump, side cover, plugs, plugs and other small parts are installed.
The assembled fuel pump is run-in and adjusted before being installed on the engine. Run-in is carried out for running-in parts and detecting assembly defects (leaks, increased heating of parts, freezing of plungers), as well as for additional cleaning of fuel channels from metal particles that could separate from the surfaces of parts during assembly. Before running in the pump, oil is poured into its crankcase and regulator.
The preliminary running-in of the pump is carried out with open tubes (without nozzles) on a mixture of oil and diesel fuel (1: 1) with the rail position corresponding to the average flow. Then a run-in is carried out on diesel fuel pumped through nozzles adjusted to operating pressure, with the position of the rail corresponding to the full supply. Before this break-in, the pump must be wiped dry to make it easier to identify leaks in the joints. The running-in is carried out at the number of revolutions of the cam shaft 500-700 per minute for 20-60 minutes. The running-in mode and time are stipulated by the technical conditions.
In the process of running in, the detected minor flaws are eliminated, fittings, nuts, plugs are tightened.
The break-in stand should be equipped with fuel filters, which are flushed after every 10-20 pumps run-in.
After running in, inspect the pump and regulator at removed covers, check the smoothness of movement of the rack and regulator parts, the longitudinal movement of the camshaft, fastening and cottering of parts, and flush the pump and regulator cavities with diesel fuel.

The run-in pump is installed on a stand to adjust the feed start angle, which ensures fuel injection into the cylinder, in strictly set moment(before the piston arrives at TDC), the same for all engine cylinders.
The beginning of the feed should be set with a deviation of no more than 0.5-1?. The start of fuel supply is determined by the position of the camshaft, at which the upper edge of the plunger closes the inlet window of the sleeve, or by the start of fuel injection by the nozzle. The start of the feed is determined by the meniscus or by the mesh disk rotating synchronously with the cam shaft.
To ensure uniform loading of all engine cylinders, the uniformity of fuel supply is adjusted by all plungers of the fuel pump. The allowable difference in the fuel supply by any plungers in the maximum feed mode should be no more than 3%, in the low feed mode at low speeds - up to 40%.
To change the amount of fuel supplied by each plunger, at a given position of the rail, the screw is released, which tightens the ring gear on the rotary sleeve, and the sleeve is turned together with the plunger to the right or left. This changes the moment of opening the inlet hole of the sleeve by the edge of the plunger spiral and, accordingly, the length of the plunger stroke.
In pumps, the plungers of which are turned not by a crown, but by a leash fixed on the plunger, the amount of fuel supplied by the plunger is regulated by the displacement of the clamp connecting the plunger leash to the rack.
If the pump adjusted at high flow does not provide the required uniformity of fuel supply at low flow, individual plunger pairs are replaced.
Regulation of uniformity of supply is carried out on a stand with a mechanical drive, providing a smooth change in the number of revolutions, through standard calibrated nozzles. The feed rate is characterized by the amount of fuel supplied through the nozzle for a certain number of plunger strokes (400, 500, 650, 750).
The number of injections is counted by the tachometer. Typically, stands are equipped with a mechanism that automatically turns off the fuel supply to the beaker after a set number of injections. After adjusting the fuel supply, the regulator is adjusted. At the same time, the start of turning off the rail and the complete shutdown of the feed at a given number of revolutions are checked.

Every driver knows that diesel and gasoline engines have various device fuel injection systems. So, the injection pump of a diesel engine is considered the most important component of the first.

TNVD: what is it?

In the people, the high-pressure fuel pump is commonly called the high-pressure fuel pump of a diesel engine. Such a unit is a very complex and indispensable structural element, since the main task of the pump is to supply diesel fuel under a fairly high pressure. The injection pump of a diesel engine, the price of which is indicated in the article, is able to provide the correct and very accurate fuel supply to the cylinders diesel engine under the right pressure. Fuel is supplied in very precisely measured portions at the most suitable time for this. Each of them perfectly matches the motor load.

Diesel injection pumps may differ in injection methods. There are products with an accumulator type of injection, as well as models of direct action.

The first devices are characterized by the fact that the working drive of the plunger is directly affected by compressed gases in engine cylinder. Or the impact can occur due to the work of the springs. Please note that there are models of hydraulic accumulator pumps that are quite common in very powerful diesel internal combustion engines.

The second type of device can be characterized as a product having mechanical drive plunger. This suggests that the phenomena of injection and injection take place simultaneously. The injection pump of a diesel engine is able to supply the correct dose of fuel to each cylinder individually.

Main causes of malfunctions

Please note that the diesel injection pump, the malfunctions of which are described below, is very expensive equipment, which is especially demanding on the quality of the fuel itself, as well as any lubrication materials. Do not forget that the use of low-quality inexpensive fuel will very quickly lead to a malfunction of the nozzle responsible for the flow of such important processes like squirting and spraying.

Symptoms

There are several signs that indicate that it is necessary to repair the injection pump. This may include:

• a significant increase in fuel consumption indicators;
• from the exhaust pipe you will notice increased smoke of an uncharacteristic color and smell;
• during operation of the motor will be issued extraneous noise and sounds;
• the output and power of the internal combustion engine drop significantly and noticeably;
• more and more often it will be noticed that the machine does not start so easily and not so quickly.

Modern diagnostic indicators

Diesel injection pump diagnostics are important measures taken to prevent problems with the engine. The most modern motor devices are equipped with a special convenient fuel injection system. Such the electronic unit control is able to meteredly supply fuel to the cylinders, while accurately distributing this process by time. This system is also able to determine how much diesel fuel is needed.

So, if the owner of the car begins to notice even the slightest interruptions in the operation of the system, then you urgently need to send your “iron friend” for diagnostics. Timely contacting a car service can affect the future repair process or equipment replacement.

During the diagnostics, car service specialists will be able to determine the following performance indicators:

• with what frequency the shaft rotates;
• how evenly the fuel is supplied;
• pressure indicators and determination of its stability.

System evolution

Everyone knows the global problems associated with the ecology of our planet. Therefore, strict standards for the manufacture of engines have led to the fact that massive mechanical injection pumps of a diesel engine, reviews of which you can read in this article, began to be replaced by modern systems that have electronic adjustment. In addition, a mechanical pump cannot provide a correct, fast and accurate supply of diesel fuel. Also, he is not able to react with lightning speed to very quickly changing modes of operation of the motor.

Popular manufacturers such as Nippon Denso, Bosch and many others are already using electronic diesel fuel management systems with might and main. In addition, the VE fuel pump took part in such developments. Usage modern systems led to the possibility of obtaining the fastest possible fuel supply separately to each working cylinder.

Many drivers liked such systems, as the instability of the combustion process of fuel-air masses decreased between cycles. Also, importantly, the unevenness in the operation of the motor on Idling. Some models were equipped with a special quick-acting valve that splits the moment of fuel injection into two phases. This process helped to reduce the harshness of the combustion itself.

Thanks to the accuracy obtained, the developers were able to ensure the minimum amount of harmful toxic emissions into the atmosphere. This is facilitated by practically complete combustion the fuel itself. But the efficiency of such a unit significantly increased the coefficient useful action motor and led to the final power. Electronic systems work thanks to the injection pump of a diesel engine (the principle of operation is described in this article). It is important to know that the high pressure fuel pump can be controlled using a special device. It allows you to adjust the position of the dispensers.

How the system works

The electronic control unit receives signals important for operation from various sensors in a timely manner. In this case, it is worth considering such characteristics as the position of the gas pedal, the temperature of the fuel, the frequency with which the engine shaft rotates, as well as the temperature of the cooling liquid. The ECU is designed in such a way that it has the ability to receive data such as vehicle speed, injector needle lift, as well as intake air temperature and pressure. The electronic control system is able to process all the information received from the sensors and transmit a signal to the high pressure fuel pump. And this, in turn, ensures the correct and timely supply of fuel to the injectors.

Also, the ECU additionally takes into account the injection angle depending on the operating conditions. motor vehicle. Even the smallest load will be noticed electronic system control, and the pump will receive a signal that it is necessary to increase the amount of fuel entering the system. Also, the ECU is able to control the activity of the glow plugs. He pays attention to parameters such as the time spent on the glow itself, as well as the time period after that. Do not forget that these processes are directly dependent on temperature.

Diesel injection pump device

Consider the device of a high-pressure fuel pump using the example of a distribution unit. The first thing to consider is that pumps are single-plunger and double-plunger. In this case, even one section of the device can supply a mixture of fuel to several nozzles at once.

So, the pump discussed in this article consists of a reduction valve, a mode controller, a drain fitting, and also a pump section housing. The device also has fuel supply elements, a housing, a hatch responsible for injection advance, as well as solenoid valve and a special plunger drive device. Of course, the high-pressure fuel pump has an efficient, but very complex device, so it will not be so easy to diagnose. But repair is generally a very difficult task, even for a well-equipped car service.

High pressure fuel pump repair

A variety of reasons can lead to breakdowns of the high pressure fuel pump. Most breakdowns are simply impossible to repair with your own hands. Even in special car service this is considered quite a difficult task to complete. But if the equipment needs to be replaced any parts, then this can be done in the garage. However, experts strongly do not recommend doing it on your own, especially without prior diagnosis. In any case, the adjustment of the injection pump of a diesel engine should be carried out using a specialized stand.

The most common cause of breakdowns is the wear of the diesel engine itself. This can be determined even by ear. A broken engine is too loud and emits strange noises. Also, each time it becomes harder to start the engine, while there are big losses power. Never use fuel Bad quality. This will affect the operation of the motor very quickly. Note that very important role for serviceability, the car electronics play.

In order to make repairs, most often you just need to replace worn parts. But even for this you need to disassemble the device. Of course, you can do this in your garage too. But if you do not have special skills, it is better not to take risks and go to a car service.

Adjustment process

Please note that the adjustment of the high pressure fuel pump should only be carried out on special stands by highly qualified workers. During this process, specially selected nozzles are usually used. Before starting the pump adjustment, all nozzles must be correctly adjusted on a special stand, taking into account all the technical parameters of this model. After the pump has been adjusted, each nozzle is installed on the cylinder of a suitable section of the device, which was regulated together with this nozzle.

How is cyclic feed regulated

A very important part of the adjustment of the high pressure fuel pump is the process of controlling the fuel supply itself at nominal speed. To do this, you need to set the pump rack to the nominal flow position using special nut. During the rated speed, it is usually measured cyclic feed each section and at the same time control the fuel level.

Operating rules: oil selection

The service life of the injection pump of a diesel engine directly depends on correct operation, as well as the fuel and other materials you use.

For the correct and long operation of the device, it is very important to fill in engine oil on time. It should ideally fit exactly to your engine and have all the characteristics it needs. Experts do not recommend changing the brand of oil very often, as this can lead to the formation of deposits that are not so easy to dissolve. Change the oil and filters once every 7500 kilometers.

Long service pledge

In order for the engine to work properly for many years, you need to follow certain rules, namely:

• Replace the timing belt in a timely manner. This must be done every 50-60 thousand kilometers.
• Change fuel filter every 10 thousand kilometers.
• It is good to warm up the engine and try not to drive at high speeds.
• Perform timely diagnostics of equipment.

A few final words

The cost of the device itself is approximately three hundred dollars (types of injection pumps for diesel engines are described in this article). In no case do not ignore the diagnosis, because even the smallest trouble can make you a victim or the culprit of traffic accidents. Carry out all repairs only in specialized services. Trust your car exclusively to highly qualified professionals. When replacing worn parts, buy only original products from the manufacturer.

Timely diagnosis and the use of high-quality materials will be the key to a long life of a diesel engine. Treat your “iron friend” with respect and diagnose all breakdowns in time. Only in this case, it will serve you for a very long time.

Do-it-yourself injection pump repair (high pressure fuel pump) may be required for any diesel engine after a certain mileage of the machine, because even those made with high precision and from wear-resistant materials, pump parts can wear out over time, and they should be restored or changed. In this article, we will consider how, in garage conditions, to make some parts of the high-pressure pump (fuel equipment) and how to restore the normal operation of the high-pressure fuel pump.

Of course, on different cars there may be design differences in fuel equipment and describe in one article the repair of pumps various brands and models are not realistic, taking into account all the nuances of the design of parts and their wear. But still, on most machines, the principle work of injection pump is the same and if there are any significant differences (for example, one plunger or several), then they will be taken into account if possible.

If you do not have locksmith skills and skills in using measuring tools, then I still advise you to contact a specialized workshop to repair your high-pressure fuel pump (especially the freshest foreign cars), and despite the fact that competent repair of fuel equipment is quite expensive, it is still worth spending money.

Well, for those who are friends with technology from an early age and are used to doing everything themselves, disassembling the mechanism of any pump and then identifying worn parts, and of course replacing them, will not be difficult. Especially on simpler diesel cars of not the most recent years of production. Of course, for a more accurate diagnosis, some devices may be needed, but some of them can be bought or made by yourself.

The injection pump of any diesel engine is a very important and high-precision unit, the condition of which directly affects normal work diesel engine. And the tasks of the pump include not only the supply of diesel fuel to under high pressure, but also the exact change in the amount of fuel (per unit of time) depending on the speed crankshaft engine. Also, with the help of a special solenoid valve installed in the high-pressure fuel pump, the diesel engine is silenced.

The task of the high pressure pump also includes vacuum adjustment of the amount of fuel required, when changing the speed, installed on the engine. Also in the pump there is a device for taking readings of revolutions (for a car tachometer).

Even in the high-pressure fuel pump there is a system for adjusting the operation of the pump (supplying the right amount of fuel) depending on the temperature of the coolant and, accordingly, the engine itself. Well, there is a vacuum control of the diesel engine speed, depending on the operation (on-off) of the air conditioner.

The pump also has a device for adjusting the minimum and maximum speed engine, also for adjusting the nominal fuel supply and changing the fuel injection advance angle (similar to the ignition advance on carburetor engines).

Knowing all the above functions (at the most modern diesels there may be additional ones) and what mechanism (part) of the pump implements them, you can easily identify a worn or faulty mechanism, in case of some kind of malfunction and eliminate it. But let's start with the smallest faults.

High pressure fuel pump repair - troubleshooting and troubleshooting.

Some of the important details HPFP, their diagnostics and troubleshooting.

Elimination of fuel leakage.

The most frequent malfunction on used diesel foreign cars over 5 years old, this is fuel leakage due to worn rubber seals (rings, cuffs). It is revealed simply: with the engine running, you need to shake the lever axis indicated by the yellow arrow (see photo below) and if there is a fuel leak, then the rubber rings should be replaced.

But it is not difficult for me to repeat in this article. First, we check whether the wire coming to the valve is broken. If it is in place, then now you should make sure why the valve does not work: due to its breakdown (jamming) or due to damage to the wire supplying voltage to it. We take a piece of wire and connect it with one end to the positive terminal of the battery, and the other end to the valve terminal.-

If a click of the valve operation is heard when a live wire is connected to it, then the valve is working and you need to look for the cause in the wiring (check the integrity of the wire from the ignition switch to the valve - it may not be the wire is damaged, but just the terminal on some connector has come off or oxidized). By connecting a separate wire from the battery to the valve, you can drive home, and at your leisure check the integrity of the wiring, or contact an auto electrician ..

If, when a separate wire (from a battery) with a voltage of 12 V is connected to the valve, no click is heard, then the solenoid valve itself has failed (the selenoid coil may have burned out, it is detected by a continuity of the coil) and it should be replaced.

Plunger distribution mechanism for fuel supply .

Sometimes it happens that the car has stood for several days or even weeks, and after trying to start the diesel engine, it does not start. This is due to the presence of water in the fuel. It happens, of course, that diesel after long parking will not start for other reasons, for example, due to vacuum battery, oxidation of its pole pins, air injection pump, problems with anti-theft, etc.

But as I mentioned above, it often happens that the engine does not start due to the presence of water in diesel fuel. It may be present in the fuel after an unsuccessful refueling, or you just have half empty tank and in winter time there will be condensation in the tank (in winter, you should always keep the tank as full as possible, or use special additives to the fuel that convert water.

So, on most high-pressure fuel pumps, for example, such well-known companies as Diesel-Kiki, Bosch, Nippon Denso, when water enters the high-pressure fuel pump, both the distributor plunger itself and its drive break, or the ball bearing of the dispenser drive breaks. The probability of breakdowns is exacerbated by the idle time of the machine with water in the injection pump. And the longer the downtime, the more likely it is to break.

Since the plunger itself, as well as other parts of the pump, is made with high precision and moves in its bore with very small gaps. And if there is water in the fuel and it gets into these gaps, the parts begin to corrode and corrosion tightly seizes friction pairs (a plunger with a dispenser and a sleeve). Engineers abroad who produce foreign diesel cars do not even think that water may be present in our fuel.

On our own diesel trucks there is a special sump filter (preliminary, coarse and fine filters, as well as nozzle filters) and water is not so terrible. Therefore, whoever does not want to have breakdowns of an expensive branded injection pump (a new branded pump costs about $ 1000-1500) and get into its expensive repair, I advise you to modify the fuel system of your diesel foreign car, as I described here.

You can avoid breakdowns: if your car has been standing for a long time (for example, you flew away on vacation) and upon arrival you are not sure that there is no water in the fuel, then I advise you not to start the engine immediately with a starter, but try first to throw off the timing belt, (apply before these marks on the belt, relative to all pulleys, or set all pulleys - crankshaft, camshaft and high-pressure fuel pump drive according to factory marks). After removing the belt, you should try to slowly scroll the injection pump pulley by hand (clockwise).

If you can turn the pulley by hand (it turns with variable resistance, that is, when the cams of the internal mechanism run up and push the plunger, the pump pulley rotates with a variable load and this is normal), then everything is in order and you can return the timing belt to its place by setting everything pulleys according to factory marks.

If it is not possible to turn the injection pump pulley by hand, then you should disassemble the pump and try to spill the plunger with kerosene in order to remove it to remove corrosion. It used to be for a long time parked cars, when water gets in, the plunger tightly sticks to the sleeve and had to be pressed out with a press. But before that, as I said, you should thoroughly fill the plunger with kerosene or water (WD-40) and wait a few hours for everything to acidify and then it may not be needed.

To get to the plunger, of course, you should remove the injection pump from the engine and disassemble it. Before removing and disassembling, I advise beginners to photograph all the stages of disassembly, this will help to assemble everything later quickly and without problems. And you should remember Golden Rule, before removing the injection pump from the engine, mark all pulleys (camshaft, crankshaft and pump) with respect to the belt (belt marks) or their marks on the engine.

To remove the pump from the engine, of course, you will need to disconnect the high pressure fuel pipes, throttle cable, hoses from the temperature sensor, wires, etc. (on some machines you will need to remove something else, we look at the place and take pictures).

Before unscrewing the two nuts holding the injection pump on the engine (on some three nuts or bolts), be sure to mark the pump flange (its exact location) relative to seat in the engine, then to install the high-pressure fuel pump as it stood (otherwise change the injection timing and there will be problems).

Before disassembling the pump, be sure to clean it from the outside with diesel fuel, and especially persistent pollution should be washed with carburetor cleaner. Washed on the outside and perfectly clean, the pump will guarantee that no dirt will get inside.

Having removed and laid the injection pump on a workbench covered with a clean white cloth or paper, turn it over with the pulley down so that when the pump head is removed, the springs and rollers with washers do not fall out. And then you will mix up the places of each video, and after all, each part has its own run-in place and it is very undesirable to change parts in places.

And so that later, when assembling, everything is correctly assembled, each removed part should be marked relative to its place, with a marker of the desired color (or numbers). And it is better to carefully remove the clip with rollers and put it in a separate place, and during assembly, all the rollers, relative to the clip, will be in place. In addition, each roller has its own washer, which is installed with the flat side to the roller.