| Removal and Installation General Equipment Cable ties Hot air gun Pneumatic vacuum gun Removal WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury. WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury. CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. | | -
Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures). | | | -
Torque: Fuel pump back plate bolt 10 Nm Fuel pump support bracket bolt 23 Nm | | | -
Remove the generator. Refer to: Generator - 1.8L Endura-DI (Lynx) Diesel (414-02 Generator and Regulator, Removal and Installation). | | | -
NOTE:Discard the fuel injection timing solenoid bolts. Clean the area around the fuel injection timing solenoid. Torque: 12 Nm | | | -
CAUTION:O-ring seals must only be removed from the fuel pump, using a blunt plastic tool. Inspect the fuel injection timing solenoid to make sure that both O-ring seals are still fitted. If the fuel injection timing solenoid O-ring seal(s) is missing from the fuel injection timing solenoid, it must be removed from the fuel pump using a suitable blunt plastic tool. | | | -
Cut the fuel injection timing solenoid wiring harness as close to the fuel injection timing solenoid as possible. | Installation | | -
To install, reverse the removal procedure. | | | -
CAUTION:Do not remove the fuel injection timing solenoid protective cover supplied with the new fuel injection timing solenoid at this stage. NOTE:Discard the fuel injection timing solenoid electrical connector. Cut the new fuel injection timing solenoid wiring harness as close to the fuel injection timing solenoid electrical connector as possible. | | | -
Secure the new fuel injection timing solenoid to the fuel injector high-pressure fuel supply line. | | | -
Install the new fuel injection timing solenoid wiring harness protective cover (supplied in the service kit) over the fuel pump fuel injection timing solenoid wiring harness. -
NOTE:The fuel injection timing solenoid wiring harness can be connected either way round and it will not affect the function of the new fuel injection timing solenoid. | | | -
CAUTION:Secure the excess fuel injection timing solenoid wiring harness using a cable tie. Make a loop with the excess fuel injection timing solenoid wiring harness and secure the loop using a cable tie. | | | -
NOTE:Install all the bolts finger tight before final tightening. | | |
