Injection pump - with intercooler (page 4 of 4)

38. Release 3 pin multiplug from adaptor bracket.
39. Remove 3 Allen screws securing adaptor bracket to FIP and remove bracket.
40. Remove fuel feed banjo adaptor from FIP and discard sealing washer.
41. Remove fuel return banjo adaptor from FIP and discard sealing washer.

CAUTION: Plug the connections.

42. Fit fuel return banjo adaptor to FIP using NEW sealing washer. tighten adaptor to 25 Nm.
43. Fit fuel feed banjo adaptor to FIP using NEW sealing washer. Tighten adaptor to 25 Nm.
44. Fit adaptor bracket to FIP and tighten Allen screws to 10 Nm.
45. Connect 3 pin FIP multiplug to adaptor bracket.
46. Lubricate and fit new ’O’ ring to fuel cut-off solenoid.
47. Clean fuel cut-off solenoid plunger and spring.
48. Fit plunger and spring to solenoid.
49. Fit solenoid to FIP and tighten to 20 Nm.
50. Connect cable to solenoid and secure terminal nut.

Refit

1. Clean mating faces of FIP and gearbox mounting plate.
2. Fit FIP to gearbox mounting plate and tighten nuts to 25 Nm.
3. Fit FIP support bracket.
4. Fit but do not tighten bolts securing bracket to engine.
5. Fit nuts and bolts securing support bracket to abutment bracket and tighten to 25 Nm.
6. Tighten bolts bracket to engine to 25 Nm.
7. Connect FIP multiplug to mounting bracket.
8. Clean injector pipes and unions.
9. Fit No 3 and 4 injector pipes and tighten unions to 20 Nm.

CAUTION: To prevent damage to fuel system pipes or components use a back up spanner when tightening unions.

10. Repeat above procedure to fit No 1 and no 2 injection pipes.
11. Fit clamp to the 4 injector pipes.
12. Connect FIP multiplug to bracket.
13. Fit fuel return pipe banjo to FIP using new sealing washers. Tighten cap nut to 25 Nm.
14. Connect fuel return hose to injector.
15. Fit fuel feed pipe banjo to injection pump using new sealing washers. Tighten bolt to 25 Nm.
16. Connect injection pump multiplugs
17. Connect injector needle lift sensor multiplug and secure to clip on abutment bracket.
18. Connect feed lead to No 2 glow plug and tighten nut to 2.5 Nm.
19. Clean injection pump drive gear and shaft.
20. Fit drive gear to injection pump.
21. Fit locking pin tool 18G 1717 to injection pump drive gear and engage into gearbox mounting plate.
22. Fit spring washer and nut to injection pump shaft and tighten to 60 Nm.
23. Loosen injection pump shaft clamp bolt.
24. Position spacer beneath clamp bolt.
25. Tighten clamp bolt to 10 Nm.
26. Fit injection pump timing belt. See ENGINE - ’L’ SERIES, Repairs.
27. Connect coolant hose to water pump and tighten clip screw.
28. Fit top hose.