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ENGINE
54
Fig 1
Fig 1a
Fig 2
Removal of HP Pump
1. Remove the fuel lines from Fuel filter to Pump.
2. Remove the back-leak pipes (pump to filter and
Injector to pump) and the electrical connections
on the pump.
(Fig: -1 & 1a)
3. Plug the fuel inlet port on the rail and fuel
outlet port and leak-off port on the pump to
avoid dust and dirt entry.
4. Unscrew the bolts (4 Nos. 2 on the block and 2
on pump)of Pump rear support and remove the
support.(Fig: - 2).
5. Unscrew the bolts (4 nos.) of the HP pump
mounting bracket which is mounted on the
timing gear housing and remove the complete
assembly (pump, gear, and pump mounting
support) with the flange and gear. (Fig 3).
6 Keep the pump assembly on a fixture and
remove the gear.
7. Using the standard tool or a 3-legged puller,
remove the pump drive gear from the shaft.
8. Slacken and remove the bolts securing the
pump to the mounting flange.
9. Separate the flange from the pump.
Installation of the Pump
1. Fit the pump on the pump mounting bracket
with the 3 screws and hand tighten initially.
Then apply torque = 20 +/- 4 Nm. Use a new
gasket.
2. Fit the gear on the pump shaft with the nut and
apply Torque= 60 +/- 8 Nm.
3. Fit this assembly on the timing gear housing
from rear side by alining the gear. Ensure it has
meshed correctly with the idler gear (behind
cam gear). Use a new gasket.
4. Align the holes on the bracket with the holes
on the timing gear housing.
5. Fit the assembly with 4 bolts. Apply a
torque=20 +/- 4Nm.
6. Fit Pump rear support bracket and apply a
torque = 33.5 +/- 5 Nm.
7. Remove the plugs on pump and rail just before
fitting the HP pipe.