Removal and installation of fuel injection pump (Mitsubishi Pajero 1)

High pressure fuel pump

Removal

1. Disconnect the wires from the battery terminals.

2. On vehicles with an air-to-air heat exchanger, disconnect the electrical wires from the electric cooling fan, disconnect the air hoses from the cooler, unscrew the four arc mounting bolts and remove the entire unit.

3. Disconnect the turbocharger compensation hose.

4. Disconnect the electrical wires from the pump (see picture High pressure fuel pump).

5. Disconnect the fuel supply and outlet pipes, fuel supply control cable and high-pressure pipes from the pump.

6. Remove the upper timing cover.



7. Rotate the crankshaft clockwise with a wrench on the pulley mounting bolt, align the marks on the camshaft pulley (1) and the fuel injection pump drive pulley with the mounting pins (2) on the block and loosen the tension of the toothed belt.





8. Unscrew the nut securing the fuel injection pump drive toothed pulley and remove the pulley (2) using the puller (1). Unscrew the two front fuel injection pump mounting bolts.

9. Remove the rear pump mounting bracket, then remove the fuel injection pump.

Installation

1. Replace the two front pump mounting bolts and install the rear pump mounting bracket.

2. Install the fuel injection pump drive toothed pulley, screw on and tighten the pulley nut to a torque of 8.0–9.0 kgf/m.

3. Place the toothed belt on the fuel injection pump drive pulley, having first aligned the installation marks.

4. Adjust the initial fuel injection advance angle of the high-pressure fuel pump as described below.

Tighten the pump mounting bolts.

5. Install the upper timing cover.

6. Connect the high-pressure lines, fuel supply control cable, fuel supply and outlet lines to the pump.

7. Connect the hose to the fuel supply corrector according to the pump boost pressure.

8. Connect the electrical wires to the pump.

9. Reinstall the air-to-air heat exchanger, if present.

10. Connect the wires to the battery terminals.

11. Start the engine and check its idling speed.

Adjusting the initial fuel injection advance angle of the high-pressure fuel pump

1. Turning the crankshaft clockwise with a wrench on the pulley mounting bolt, set the piston of the 1st cylinder to TDC at the end of the compression stroke.

2. In this case, the mark on the crankshaft pulley should be opposite the TDC ("TDC") mark on the lower cover of the timing gear drive.

3. Unscrew the threaded plug, which is located at the rear of the pump between the high-pressure pipe fittings.



4. Screw the MD 998384 stand into the hole for the plug, after making sure that its movable pin protrudes by 10 mm (1 – indicator, 2 – high-pressure fuel pump).

5. Attach the indicator to the end of the post.

6. Turn the crankshaft counterclockwise so that the piston of the 1st cylinder is set at approximately 30° before TDC.

7. In this position, set the indicator arrow to zero. By turning the crankshaft slightly in both directions, make sure that the indicator needle does not respond.

8. Otherwise, repeat the previous operation.

9. Turning the crankshaft clockwise, align the mark corresponding to the fuel injection advance angle at 2°, 5° and 7° after TDC (depending on the engine model), on the crankshaft pulley with an alignment mark on the lower cover of the timing drive.



10. In this position the indicator should show 1±0.03 mm.

11. If the indicator shows a different value, loosen the two front pump mounting bolts and the rear pump bracket mounting bolts.

12. Loosen the high pressure line fittings.

13. If the indicator reading is less than the required value, move the pump towards the engine and vice versa.

14. Tighten the front pump mounting bolts and the rear pump bracket mounting bolts.

15. Tighten the high pressure line fittings.

16. Remove the indicator and unscrew the indicator stand from the pump.

17. Screw the threaded plug into the pump hole, having first replaced the gasket.