Note: Observe the precautions given in Chapter 1. For the initial installation of the fuel pump, you will need a suitable micrometer and adapter.
Withdrawal
1. Disconnect the negative cable from the battery.
2. Where necessary, loosen the nuts and remove the cover from the top of the motor.
3. Remove the camshaft cover as described in Section 1A.
4. Unscrew the mounting bolts and remove the cover from the rear of the engine to gain access to the fuel pump drive belt (see illustration).
5. Set piston No. 1 to TDC as described in Section 1A, However, before removing the fuel pump drive belt and sprocket at the rear of the camshaft, mark the location of the TDC mark on the high pressure fuel pump sprocket/pulley in relation to the pump housing. Also note the location of the fuel pump relative to the bracket (see illustration). Cm. Section 1A for the fuel pump drive belt removal procedure, however, it is not necessary to install the lockout pin as it is only required when performing the toothed drive belt installation procedure.
6. Loosen the bolt/nut securing the sprocket and pulley to the camshaft and fuel pump drive shaft one or two turns. To do this, hold each sprocket using the appropriate tool (see illustrations).
7. To remove the fuel pump sprocket, screw a suitable extractor to it. After releasing the sprocket, completely unscrew the nut and remove the sprocket. Remove the key from the drive shaft (see illustrations).
8. Remove the union nuts securing the fuel lines to the injectors and high pressure fuel pump and remove them as a complete set. Cover the fuel lines to prevent dust and dirt from entering the fuel system (see illustrations).
9. Turn off bolts of the coupling, and disconnect submitting and returnable fuel hoses from the fuel pump.
10. Remove seal washers.
11. Note the location of the electrical wiring on the high pressure fuel pump, then disconnect it.
12. Mark the location of the fuel pump relative to the bracket to facilitate installation. Loosen the pump mounting bolts and remove the fuel pump from the bracket (see illustrations).
13. Position the fuel pump on the bracket and insert the mounting bolts. Rotate the pump as needed until the mounting bolts are centered on the elongated bracket holes, then tighten the bolts to the specified torque specifications. The factory alignment marks should line up at this stage (see illustrations). These marks will remain aligned for static timing adjustment, but during dynamic timing adjustment the fuel pump may be moved so that the marks are not aligned with each other.
14. Install the fuel pump sprocket/pulley and key on the drive shaft, and tighten the nut to the specified torque specifications, while holding the sprocket with the tool used to remove it (see illustration).
15. Install the sprocket on the rear of the camshaft, insert the bolt with washer, and tighten it with the tightening torque regulated specifications, while holding the sprocket with the tool.
16. Install and tension the fuel pump drive belt as described in Section 1A. Please note that the precise adjustment of the injection timing depends on the correct installation and tension of the drive belt.
17. Reset the engine and fuel pump to TDC, then loosen the sprocket bolt on the rear of the camshaft one turn so that the sprocket can be rotated freely on the camshaft.
18. Loosen and remove the injection timing adjustment plug on the front of the fuel pump, and install a micrometer. This will require a suitable adapter (see illustrations).
19. Make a preset so that the micrometer reads 1 mm. Then determine the BDC position of the pump piston by slowly turning the fuel pump pulley in both directions. Note that the TDC mark on the pulley is the TDC mark for the engine, but in fact at this position the pump piston starts to rise from the BDC position. This can be a bit confusing, so it's important to watch the micrometer pointer move to ensure the pump is accurately seated at BDC. The fuel pump can be rotated with a suitable tool inserted into the holes in the sprocket on the rear of the camshaft.
20. With the pump at BDC, reset the micrometer to zero, then slowly turn the fuel pump counterclockwise (when viewed from behind), until the micrometer shows the value indicated in Specifications value for injection timing (after BMT) fuel pump piston (see illustration).
21. Check that the TDC mark on the flywheel / drive plate is aligned with the slot in the transmission, then carefully tighten the bolt securing the sprocket to the rear of the camshaft with a tightening torque regulated specifications. While doing this, hold the sprocket with a tool. Be careful not to disturb the installation of the fuel pump.
22. Rotate the crankshaft two full turns clockwise and align the TDC marks on the flywheel/drive plate and transmission. Do not turn the crankshaft past the TDC marks.
23. Note the result on the micrometer. Due to the tension of the toothed drive belt, the result obtained will be slightly less than the derived value. If the result is outside the specified limits, repeat the installation procedure.
24. Remove the micrometer and adapter, then install and tighten the plug with the tightening torque specified specifications.
25. Connect electrical wiring to the fuel pump.
26. Connect the couplings of the supply and return fuel hoses together with new washers, and tighten the couplings with the torque specified specifications.
27. Connect the fuel lines to the injectors and the high pressure fuel pump, and tighten them with a tightening torque regulated specifications.
28. Install the fuel pump cover on the back of the engine.
29. Install the camshaft cover as described in Section 1A.
30. Connect the negative wire to the battery.
31. Ideally, the fuel pump now needs to be primed. To do this, disconnect the fuel return coupler from the top of the pump, and connect the vacuum pump with a 1.0 meter long plastic tube through an adapter. Bleed the vacuum pump until fuel flows out of the return hole. Be careful not to get fuel into the vacuum pump. Finally, connect and tighten the fuel return coupler.
32. Start the engine and check the fuel system for leaks.
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