Warning. Do not attempt to perform injection advance adjustment procedures without accurate instruments. The appropriate special tools for adjusting the injection pump timing can be purchased at major auto parts stores or from your Peugeot/Citroen dealer. Before starting work, please read the safety precautions described in paragraph 1 this chapter.
Note: To check the injection advance of the high-pressure fuel pump, a dial indicator (Peugeot/Citroen special tool No. 3089-T) is required together with a special installation probe (Peugeot/Citroen special tool No. 5003-TD) and an adapter (Peugeot/Citroen special tool No. 7010-T). Without this equipment (or an appropriate alternative) the procedure for checking and adjusting the injection advance of the high-pressure fuel pump should be entrusted to a Peugeot/Citroen dealer or other specialist who has the appropriate equipment.
1. If the fuel injection advance is being checked without removing the pump from the engine, rather than during the pump installation procedure, disconnect the battery ground cable (see "Disconnecting the battery") and cover the generator with a clean cloth or plastic bag to protect it from possible fuel spills.
2. Remove the air intake duct between the air distribution housing and the air cleaner assembly as described in paragraph 3.
3. Remove the fuel injector lines as described in paragraph 5.
4. Disconnect the electrical connectors on the rear of the high pressure fuel pump.
5. Loosen the clamp screw and/or nut (whichever is applicable) and slide the high idle speed cable end along the cable so that it is no longer in contact with the high idle speed lever on the pump (that is, so that this lever returns to the limiter) (see paragraph 4).
6. Align the engine assembly/camshaft timing marks (see chapter 2B) to lock the crankshaft. Remove the crankshaft locking tool and then turn the crankshaft backwards (counterclockwise) approximately a quarter turn.
7. Unscrew the service plug located in the center between the four union nut connections of the injector lines on the back of the high-pressure fuel pump. After unscrewing the plug, place a suitable container under the pump to collect the leaking fuel. Wipe up any spilled fuel with a clean cloth.
8. Screw the adapter into the back of the pump and connect the dipstick to the dial indicator. Install the indicator and probe into the adapter (figure 8.8). If you do not have specific Peugeot/Citroen tools, suitable alternative tools can be purchased from many good auto parts stores. Position the indicator so that its plunger is at the mid-stroke and tighten the adapter locknut securely.
Figure 8.8. Dial indicator, adapter and installation probe for use on a Bosch pump
9. Slowly rotate the crankshaft in both directions, observing the dial indicator to determine when the high-pressure fuel pump piston reaches the bottom of its stroke (BDC). Once the piston is correctly positioned, reset the dial indicator to zero.
10. Slowly turn the crankshaft in the correct direction of rotation until the crankshaft locking tool can be reinstalled.
11. The reading on the dial gauge should be equal to the fuel pump injection advance value specified in "Specifications" at the beginning of this chapter. If adjustment is necessary, loosen the front and rear pump mounting nuts and bolts and slowly rotate the pump body until the point where the dial indicator reads the specified value is reached. Once the pump is properly positioned, tighten the front and rear nuts and bolts securely.
12. Turn the crankshaft 1% of a revolution in the normal direction of rotation. Determine the BDC position for the high pressure fuel pump piston as described in paragraph. 6, and reset the indicator to zero.
13. Slowly turn the crankshaft in the correct direction of rotation until the crankshaft locking tool can be reinstalled (to return the engine back to the TDC position). Check the injection advance again.
14. If adjustment is required, loosen the pump mounting nuts and bolts and repeat steps 11–13.
15. Having set the correct injection advance of the pump, unscrew the adapter and remove the dial indicator and dipstick.
16. Screw in the technological plug (with a sealing washer) into the pump and tighten it securely.
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17. If this procedure is performed as part of the pump installation sequence, proceed as described in paragraph 5.
18. If the procedure is performed without removing the pump from the engine, connect the fuel lines of the injectors, tightening their union nuts to the specified torque. Install the air intake duct. Connect the battery and then bleed the fuel system (see paragraph 2).
19. Start the engine and adjust the idle speed and stall prevention speed as described in paragraph 9. Also adjust the high idle speed cable as described in paragraph 4.