If there are doubts in correctness of functioning of a fuel supply system, then it is necessary to check its technical condition and to execute the following preliminary checks:

1. Make sure that in a tank there is a fuel.

2. At the working engine examine whether there is no leak on all sites of the fuel pipeline and connections of hoses from the fuel tank to the fuel pump. Tighten all weakened connections. Examine all hoses on existence of flattening or excesses which can reduce their gleam and interfere with fuel pass. Podsasyvaniye of air or an obstacle for fuel from the reception party of the fuel pump strongly influence productivity of the fuel pump.

For reduction of risk of emergence of the fire and getting injured before to start service of any elements of fuel system, it is necessary to take off previously pressure in system as follows:

– remove a stopper from a toplivonalivny mouth of the fuel tank therefore pressure in the fuel tank will be leveled with atmospheric;

– get a safety lock of the fuel pump from the block of safety locks in interior of the car;

– launch the engine and leave it to work until the stop connected with lack of fuel in the distributive fuel highway. Include a starter on 3 with for the guaranteed reduction of residual pressure;

– at the switched-off ignition establish a safety lock of the fuel pump into place;

– as a result of the performed operations pressure in fuel system is taken off. Close any connection of fuel system pure rags and, being careful, smoothly unscrew a connecting nut;

– if not to perform these operations before works on service of fuel system, spraying of fuel at separation of elements of fuel system is possible;

– after completion of works on service of fuel system launch the engine and check all connections which were disconnected, for fuel dribble existence.

1. Productivity of the fuel pump is checked by connection of a hose of supply of fuel to throttle knot and suitable unbreakable capacity. Give tension from the rechargeable battery to the test socket of the fuel pump (the G plug to the ALDL panels).

2. For 15 about the pump has to pump up not less than 0,23 l of fuel.

3. If productivity of the pump is less than specified, check whether there are no obstacles in the fuel pipeline. If there are no obstacles, check pressure created by the fuel pump.

This check has to be made by search of malfunctions in a fuel supply system.

       PREVENTION

For reduction of risk of emergence of the fire and getting injured before to start service of any elements of fuel system, it is necessary to take off previously pressure in system.

You make removal of pressure in system as follows:

– remove a stopper from a toplivonalivny mouth of the fuel tank therefore pressure in the fuel tank will be leveled with atmospheric;

– get a safety lock of the fuel pump from the block of safety locks in interior of the car;

– launch the engine and leave it to work until the stop connected with lack of fuel in the distributive fuel highway. Include a starter on 3 with for the guaranteed reduction of residual pressure;

– at switched off, ignition establish a safety lock of the fuel pump into place.

1. Take two steel call with a diameter of 9,5 mm and 254 mm long. Razvaltsuyte one end of each tube.

2. Establish a special connecting nut on the razvaltsovanny end of each tube. Connect each of nuts adapters like "Nut of a razvaltsovanny branch pipe – a nut of a razvaltsovanny branch pipe". These adapters are available in a set of adapters for the J29658 manometer.

3. Connect tubes with adapters to the J29658 manometer.

4. Lift the car.

5. Disconnect a hose of supply of fuel from the fuel pipeline under the car bottom.

6. Connect section of a tube 254 mm long and with a diameter of 9,5 mm to a fuel supply hose.

7. Connect a forward hose of supply of fuel to the second end of a tube. Record connections of hoses collars.

8. Launch the engine and check for lack of leak of fuel.

9. Take readings of pressure on the manometer which has to be ranging from 62 to 90 kPa.

10. Take off pressure in fuel system. Remove the manometer and adapters. Again connect hoses to the pipeline and tighten collars the moment of 1,7 N • m.

1.1. Lower the car, launch the engine and check that fuel does not leak.

1. Disconnect a wire from the negative plug of the rechargeable battery. In a working zone there has to be a dry chemical fire extinguisher (class B).

2. For pumping out of the greatest possible amount of fuel through a mouth of a tank use the manual pump.

3. If the fuel which remained in a tank does not manage to be pumped out the manual pump, finish operation with the help of the siphon connected to a branch pipe of supply of fuel on the fuel pump or to the fuel level sensor.

4. Establish earlier removed hoses, pipelines and a cover.

       PREVENTION

Do not merge fuel in open capacity and you do not store in such capacity in view of danger of fire or explosion.

1. Merge all fuel from the fuel tank.

2. Support by a jack through wooden whetstone the fuel tank and disconnect two tape collars of fastening of a tank.

3. Lower a tank so that it was possible to disconnect a wire of the fuel level sensor, hoses and, in the presence, a flat wire of connection with "weight".

4. Remove the fuel tank from the car.

5. Remove the fuel level sensor from the fuel tank.

1. Installation is carried out to the sequences, the return to removal.

2. At installation it is necessary to use a new sealing ring of round section.

3. At repeated installation of the fuel tank be convinced that on the top part of a tank the shock-absorbing laying weakening knocks and extraneous noise is established.

Fig. 5.3. Fuel tank: 1 – nut; 2 – tape collar

4. Tighten bolts with washers of fastening of tape collars of the fuel tank (fig. 5.3).

       PREVENTION

Even in the empty fuel tank there are fuel vapors which are explosive therefore be careful.

Any repair of the fuel tank or toplivonalivny mouth has to be carried out by the expert who has experience of performance of critical and potentially dangerous works. Even after cleaning and washing of the fuel tank in it there are explosive vapors of fuel.

If malfunctions are caused by pollution of fuel or presence of foreign substances at a tank, it is necessary to clear the fuel tank. If the tank rusted from within, it should be replaced.

1. Disconnect a wire from the negative plug of the rechargeable battery.

2. Disconnect the socket of wires from the ignition lock. In a zone of works install the dry chemical fire extinguisher.

3. Take off pressure in fuel system.

4. If in the fuel tank there is a fuel, pump out it. You carry out pumping out of fuel by the special pump.

5. Remove the fuel tank.

6. Remove the fuel filter located outside of the fuel tank and check for existence of pollution. If the filter is polluted, replace it.

7. The removed fuel tank has to be located far from naked flame, scintillating devices, open fire-dangerous light devices and places of smoking. Remove the fuel level sensor and the fuel pump assembled and check a condition of the mesh filter. If the mesh filter is polluted, replace it.

8. Finish discharge of fuel by rocking of a tank and production of fuel through an opening for the sensor.

9. Wash out the fuel tank a stream of hot water within, at least, 5 min. Merge water through an opening for the sensor (shake a tank to be convinced that all water is merged).

10. Disconnect the fuel highway and blow it compressed air. Give air in the direction opposite to a normal stream of fuel. On the cars equipped with the line of return of fuel clear the fuel highway similarly.

Disconnect the highway at throttle knot and clear the line of return of fuel compressed air. Again connect all highways and tighten connecting nuts of fastening the moments of 30 N • m.

11. Clear branch pipes of the fuel level sensor air under low pressure.

12. If necessary install the new mesh filter on knot of the fuel level sensor. Establish knot of the fuel level sensor and the fuel pump with new laying in the fuel tank and install the fuel tank on the car. Connect the socket to the fuel level sensor. Connect all fuel highways, except for the highway of supply of fuel, to the fuel filter located outside.

13. Disconnect a hose of supply of fuel from the pipeline on a forward part of a body. Connect other hose to the forward end of a hose of supply of fuel and place other end of a hose in a canister for fuel with a capacity of 3,8 l.

14. Connect a wire to the negative plug of the rechargeable battery.

15. Fill the fuel tank of 24 l of pure fuel and give voltage of 12 V to the ALDL socket plug G for turning on of the fuel pump. Pump over about 2 l of fuel in a canister. This operation will provide washing of the fuel pump.

16. Remove a hose and connect a fuel hose to the pipeline in a forward part of a body.

17. Check all connections for lack of leaks.

Washing of the fuel tank has to be carried out before repair of the fuel tank.

1. Remove the fuel level sensor and the fuel pump and merge the fuel remains from a tank.

2. Visually examine a tank from within. If the fuel remains are visible, merge it.

3. Install a tank on the flushing stand.

4. Fill a tank up to the top with tap water, strongly stir up it and merge water.

5. Fill in gasoline emulsifier in a tank, again fill with water and stir up mix within 10 min., then merge liquid from a tank.

For the correct dosage of emulsifier in water address reference materials of the producer of emulsifier. It is also possible to use the available equivalent emulsifier.

6. After discharge of liquid fill a tank with water. Completely wash away the remained emulsifier mix with water.

7. At an opportunity use the sensor of potential of explosion; the sensor has to show lack of danger of explosion.

8. Carry out the required repair work.

Close all openings of the fuel tank. Before removal of the fuel tank for check on lack of leaks examine all fuel lines and connections in fuel system to be convinced that the fuel tank can be the only source of leak of fuel.

If fuel proceeds from the fuel tank, replace the fuel tank.

Give air under low pressure to a tank through a ventilating branch pipe (pressure about 7-10 kPa). Check the repaired site for leaks by means of soap solution or immersion of the fuel tank in water. In the presence of a leak replace a tank.

Control of a butterfly valve is exercised by means of a cable, at the same time it is not required to carry out adjustments of connecting links. In view of lack of need of adjustments it is necessary to apply the cable which is specially intended for this purpose.

Upon completion of works of a control system of a butterfly valve it is necessary to be convinced of correctness of installation of all details after dismantling and of lack of friction and sticking.

At work on a cable of an accelerator it is necessary to carry out the following rules:

– the stopper has to be established so that pads were bent on a pin head;

– fastenings of a cover on both ends of a cable have to have the fixing pads filled in the corresponding openings;

– a wattled part of a cable of an accelerator assembled should not concern a forward part of consolidation of a partition at assembly, repair or removal of a cable;

– flexible parts of system (hoses, wires, tubes, etc.) should not be placed at distance closer than 50 mm from moving parts of knot of management of a butterfly valve and external parts of support in case their exact laying is not provided;

– at a detachment or replacement of details always grease axes.

At work on a pedal of an accelerator it is necessary to carry out the following rules:

– the assembly site between a support and a partition of a motor compartment has to be free from isolation. The carpet and laying in a zone of a pedal and the channel have to be laid exactly, without wrinkles and swellings;

– pass an accelerator cable through a groove in the lever, then install a stopper in the lever, having convinced that the stopper is in required position. At installation of a stopper in the lever it is necessary to show care not to carry too far or damages of a cable;

– after fastening of all details of the drive of a butterfly valve be convinced that the drive moves freely, without jamming, in all range – from completely closed butterfly valve to completely open;

– wires, hoses, cables and other details should not be at distance closer than 13 mm from a cable of an accelerator or the lever at any provision of a butterfly valve.