Withdrawal
1. Remove the injection pump cover.
2. Set the piston of cylinder N1 to TDC. Mark the position of the TDC mark on the pump pulley/sprocket (1) in relation to the pump housing. Mark the position of the housing in relation to the TDC mark on the mounting bracket (2).
3. Loosen the fixing bolt while holding the sprocket.
4. Hold the injection pump pulley stationary with a similar tool.
5. Loosen the nut and remove the sprocket/pulley.
6. Remove the dowel.
7. Unscrew the connection nuts and remove the fuel pipes.
8. Close the ends of the tubes.
9. Disconnect the fuel hoses from the pump.
10. Tag and disconnect the wires from the injection pump.
11. Unscrew the mounting bolts and remove the injection pump from the mounting bracket.
Installation and adjustment
1. Install the injection pump on the mounting bracket, aligning the mounting marks (arrows).
2. Tighten the mounting bolts (arrows).
3. Install the sprocket/pulley and tighten the fixing nut.
4. Install the drive belt.
5. Set the crankshaft and pump to TDC.
6. Remove the mounting plug from the pump.
7. Install adapter.
8. Install dial gauge.
9. Set the gauge needle to 2 mm, then set the pump piston to TDC by rotating the pump pulley.
10. Zero the sensor. Slowly turn pump rear sprocket counterclockwise until gauge reads 0.42mm (AVR engine) or 0.32 mm (AAT engine). This is a preliminary value.
11. Check that the TDC mark on the flywheel/drive plate is aligned with the hole in the transmission housing. While holding the sprocket, tighten the sprocket mounting bolt to the correct torque.
12. Turn the engine crankshaft two revolutions and align the marks on the flywheel/drive plate and gearbox again.
13. Check that the gauge shows 0.35±0.02 mm (AVR engine) or 0.25±0.02 mm (AAT engine). Repeat the adjustment if necessary.
14. Connect fuel pipes, hoses and wires.
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