300Tdi Discovery
Tdi
13
REPAIR
Refit
21. Remove blanks from pump.
22. Remove special tool pin from pump.
23. Clean mating faces of pump and front cover.
24. Fit pump to cover with a new gasket and secure
with nuts. Tighten to
25 Nm.
25. Attach pump to bracket and finger tighten nuts
and bolts
26. First tighten bolts securing bracket to block and
then bolts securing pump to bracket.
27. Connect spill return, main fuel pipes. Tighten to
25 Nm.
28. Connect boost signal pipe and secure with banjo
bolts. Tighten to
10 Nm.
29. Connect stop control solenoid lead.
30. Connect throttle cable and where applicable
hand throttle cable.
31. Remove special tool LRT-12-045.
32. Fit gear lock plate.
33. Fit pin from special tool LRT-12-045.
34. Secure gear with bolts.
35. Remove special tool pin.
36. Turn crankshaft two complete revolutions, check
timing pin from LRT-12-045 can be fully and
easily inserted into the pump. At the same time
check flywheel timing pin LST-12-044 can also
be inserted in the flywheel slot.
37. If, with the flywheel timing pin located, the timing
pin cannot be inserted cleanly into the injection
pump, carry out the following:
(a)
Ensure flywheel timing pin is disengaged
from slot in flywheel.
(b)
Turn the crankshaft the small amount
necessary to enable the timing pin to be
inserted into the pump.
(c)
Loosen the three pump gear retaining
bolts.
(d)
Turn the crankshaft to T.D.C..
(e)
Check that the timing pin is an easy fit in
the pump and that the flywheel timing pin
locates.
(f)
Tighten the pump gear retaining bolts to
the correct torque.
(g)
Remove the timing pin from the pump and
the timing tool from the flywheel housing.
38. Using antisieze compound, fit the blanking plug
to flywheel housing. Tighten to
12 Nm.
39. Fit access plate with gasket to front cover plate.
Tighten to
25 Nm.
40. Refit injector pipes. Tighten to
29 Nm.
