Table of contents: Removal ↓ Installation ↓
Removal
1. Remove the plastic cover.
2. Mark and disconnect the wires from the injection pump. Disconnect the cables.
3. Disconnect the fuel hoses from the pump.
4. Unscrew the connection nuts and remove the fuel pipes.
5. Remove the pump housing.
6. Set the piston of cylinder N1 to TDC.
7. Remove the drive belt.
8. Loosen the pump sprocket mounting nut and remove the sprocket using a puller.
9. Loosen the mounting bolts and remove the pump.
Installation
1. Install the injection pump onto the mounting bracket and tighten the mounting bolts.
2. Install the sprocket/pulley and tighten the mounting nut.
3. Install the drive belt.
4. Set the engine crankshaft and pump to TDC. Loosen the rear sprocket mounting bolt.
5. Remove the mounting plug from the pump and install the dial gauge.
6. Set the gauge pointer to 2 mm, then set the pump piston before the TDC position by rotating the pump pulley.
7. Zero the sensor. Slowly turn the rear sprocket of the pump counterclockwise until the sensor shows 1.00±0.02 mm. This is the preliminary value.
8. Check that the TDC mark on the flywheel/drive plate is aligned with the hole in the transmission case. While holding the sprocket, tighten the sprocket mounting bolt to the specified torque.
9. Rotate the engine crankshaft two revolutions and again align the marks on the flywheel/drive plate and gearbox.
10. Take the sensor reading and subtract the resulting value from the preliminary value.
11. Loosen the rear sprocket mounting bolt again.
12. Set the gauge pointer to 2 mm, then set the pump piston before the TDC position by rotating the pump pulley.
13. Zero the sensor. Slowly turn the rear pump sprocket counterclockwise until the sensor reads 1.00 mm plus the difference determined in step 10.
14. Check that the TDC mark on the flywheel/drive plate is aligned with the hole in the transmission case. While holding the sprocket, tighten the sprocket mounting bolt to the specified torque.
15. Rotate the engine crankshaft two revolutions and again align the marks on the flywheel/drive plate and gearbox.
16. Check that the sensor shows 1.00±0.02 mm.
17. Remove the sensor and screw the plug back into place.
18. Connect the fuel lines, hoses and wires.
(Read the original source on the website: AUDIMANUAL)