High-Pressure Fuel Pump

Removal and Installation PROCEDURE 1. Set the No. 1 piston to TDC and remove the camshaft drive belt (see paragraphs 4–10 of subsection 2.2.3). 2. Loosen the nut securing gear 15 (see figure Camshaft Drive Components) of the fuel pump. 3. Using a special puller, slide gear 15 off the tapered section of the pump shaft. 4. Remove the puller, unscrew the gear retaining nut, remove gear 15, and remove the key from the shaft groove. 5. Disconnect the fuel lines from the fuel pump. On the Bosch pump, the fuel supply and standard return line nuts are the same diameter, but the return line nut has a rubber seal and is marked "Out". This nut should not be replaced. 6. Disconnect the fuel supply and starting device linkage rods. 7. Unscrew the three pump mounting bolts 13 to bracket 14 and one pump mounting bolt to rear bracket 12. 8. Remove the pump. The high-pressure fuel pump is not serviceable. If faulty, replace the pump.

Installation PROCEDURE 1. Install pump 13 on bracket 14 so that the marks on the bracket and pump housing align. 2. Install the pump mounting bolts to the front 14 and rear 12 brackets and tighten to 25 N·m torque. 3. Insert the key into the pump shaft groove, install gear 15, and tighten the gear retaining nut to 45 N·m torque. 4. Connect the fuel lines and tighten the fuel line nuts to 25 N·m torque.

5. Turn the pump gear so that the mark on the gear aligns with the mark on bracket 14, as shown in the figure.

6. Lock the high-pressure fuel pump gear (2) by screwing special rod (1) into the threaded hole of the gear, as shown in the figure (3 – front high-pressure fuel pump bracket). 7. Loosen the camshaft gear retaining bolt by half a turn. Tap the camshaft gear with a rubber mallet to loosen its fit. 8. Check that the No. 1 piston is at TDC. 9. Install camshaft drive belt 6 and tension it (see paragraphs 10–13 of subsection 2.2.3).

10. Check and adjust the fuel pump injection timing.