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. 2437-T) is required together with a special installation gauge and support bracket (Peugeot/Citroen special tool no. 4O93-TJ) (figure 7.4). 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 rotor with a clean cloth or plastic bag to protect it from possible fuel spillage. Remove the fuel injector lines as described in paragraph 5.
2. Set 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.
3. Unscrew the process plug from the guide on the top of the pump body and remove the sealing washer (figure 7.3). Insert the special installation probe into the guide, making sure that it fits correctly onto the surface of the sealing washer on the guide.
Figure 7.3. Removing the technological plug from the hole for adjusting the injection advance of the high-pressure fuel pump (lucas pump)
Note: To ensure accurate measurement, the feeler gauge must fit against the surface of the guide sealing washer, not the top edge of the guide.
4. Attach the bracket to the pump guide and securely attach the dial indicator to the bracket so that its tip comes into contact with the lever mechanism of the bracket (figure 7.4). Position the indicator so that its plunger is in the middle of its stroke, and then reset the reading to zero.
Figure 7.4. Pointer indicator for adjusting the injection advance of the high-pressure fuel pump (4) and the corresponding support bracket (3), secured to the high-pressure fuel pump
5. Slowly turn the crankshaft in the correct direction of rotation (along the nasal arrow) enough to allow the crankshaft locking tool to be reinstalled.
6. With the crankshaft locked, read the indicator; the reading should match the value indicated on the pump (there is a tolerance of +0.04 mm). The injection advance value can be indicated on a plastic disc attached to the front of the pump, or alternatively on a tag attached to the pump control handle (figure 7.6).
Figure 7.6. High-pressure fuel pump injection advance values indicated on the plate (1) and tag (2) (lucas pump)
7. If adjustment is required, loosen the front nuts and rear pump mounting bolt, then slowly rotate the pump body until the point where the dial indicator reads the specified value is reached. Once the pump is positioned correctly, tighten the front nuts and rear bolt to the specified torque.
8. Slightly pull out the feeler gauge so that it is positioned away from the pump rotor dowel pin and remove the crankshaft locking rod. Turn the crankshaft 1% of a revolution in the normal direction of rotation.
9. Reinsert the feeler gauge, making sure it is properly seated on the sealing washer surface of the guide and not on the top edge, then zero the indicator.
10. Slowly turn the crankshaft in the correct direction of rotation until the crankshaft locking tool can be reinstalled. Check the injection advance again.
11. If adjustment is required, loosen the nuts and pump mounting bolt and repeat steps 11. p. 7-10.
12. When the pump injection advance is set correctly, remove the dial indicator and support bracket and take out the dipstick.
13. Screw in the screw (with a sealing washer) into the guide and tighten it securely.
14. If this procedure is performed as part of the pump installation sequence, proceed as described in paragraph 5.
15. 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. Connect the battery and then bleed the fuel system (see paragraph 2). Start the engine and adjust the idle speed and stall prevention speed as described in paragraph 9.