SAFARI

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.