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leva_bomba_gasolina

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  1. 1. 2.0T FSI Owner’s Finally piece of mind! Upgrade to H2Sport’s Fuel Pump Drive Kit and finally do away with the problematic stock cam follower for our maintenance free and worry free solution. The Basics Replace the flat face cam follower with a maintenance free andworry free roller follower. The roller follower virtually eliminates all wear-causing friction. The upgrade is intended to be an install and forget upgrade. The Upgrade Kit ContentsNew Roller Cam Follower – to replace the stock flat face followerNew Cam Lobe with revised contour – for proper fuel pump operation with new followerNew Fuel Pump Mount – to fit larger roller followerNew Fuel Pump Return Spring – for proper follower/cam dynamicsModified End Cover – to fit new Fuel Pump MountOptional:New ‘B’ Spec camshaftIf your car has an ‘A’ spec cam you’ll need to send it to us for modification. H2Sport Inc. 1 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  2. 2. The ProcessRead on for the nitty-gritty details.Our kit works with A and B spec cams. However, if you have an A spec cam you’ll needto send it to H2Sport for modification.The Cam End Cover (arrow) needs modification to fit the new roller assembly.H2Sport will modify your end cover unless you specify the core exchange option whichresults in less down time for the upgrade but you don’t get your original cover back. H2Sport Inc. 2 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  3. 3. The original cam lobe (arrow) must be remove and replaced with H2Sport’s new revisedlobe.There’s 2 ways of doing this: Remove the cam and send it to H2Sport or; Leave the cam in place and install the lobe yourself using the tool kit from us. We require a deposit on the tool kit which will be refunded upon return of the tool kit in good condition. Instructions for this option follow. H2Sport Inc. 3 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  4. 4. Basic Installation Instructions - Cam in Car:Disassembly:NOTE: You will be working with open fuel lines and fuel vapours will be present. Noopen flames or sparks permitted.Allow engine to cool, ideally to room temperature.Disconnect battery ground cable.Disconnect pressure sensor connector and pressure regulator solenoid connector. H2Sport Inc. 4 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  5. 5. Disconnect connector to cam adjuster solenoid. Unclip harness clamp and set harness offto the side. Remove 2 bracket screws. H2Sport Inc. 5 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  6. 6. Relieve fuel pressure at Schrader valve if equipped. If not, crack fuel pressure sensorloose and relieve pressure then re-tighten.Crack high pressure fitting loose to relieve fuel pressure. Use shop rags to collect fuel.Do not proceed until all fuel pressure is relieved. H2Sport Inc. 6 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  7. 7. Completely disconnect fuel lines from fuel pump. Image below shows fuel lineconnected with banjo bolt. Newer versions use a short rubber hose secured with springclamps. Cover open fuel line ends with clean shop rags.Remove Fuel Pump. Set aside in clean area and cover with clean shop rags. H2Sport Inc. 7 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  8. 8. Remove vacuum pump: 3 screws. H2Sport Inc. 8 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  9. 9. Remove End Cover – 6 perimeter bolts - and the various cable brackets attached to it.Some oil will drain out – collect with shop rags. H2Sport Inc. 9 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  10. 10. Locate dimple on intake cam sprocket. Turn crankshaft clockwise until dimple pointstowards exhaust cam and slot is roughly horizontal. In this position, one lobe of the camshould point down. H2Sport Inc. 10 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  11. 11. Install puller onto cam lobe with arm pointing up, careful of the plastic chain guides. H2Sport Inc. 11 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  12. 12. H2Sport Inc. 12 203 Guelph Street,Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  13. 13. Tighten bolt on puller to pull the cam lobe off the cam. Counter hold puller to preventcam from rotating else you risk damaging the plastic chain guides. H2Sport Inc. 13 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  14. 14. With lobe removed, lightly clean the end of cam with scotch brite. H2Sport Inc. 14 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  15. 15. Assembly:End of cam will feature a slight stepped diameter. Measure the larger diameter (which isclosest to the sprocket and is about ¼” wide) with a metric micrometer accurate to0.01mm. AN ACCURATE MEASUREMENT IS CRITICAL TO THE SUCCESSFUL OPERATION OF THE UPGRADE KIT.Each cam will measure slightly different however the range is typically Ø30.25mm toØ30.35mm H2Sport Inc. 15 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  16. 16. Choose the closest sized cam lobe - without going over - from kit and insert it into brassinstall tool with chamfer facing up. White paint marks indicate chamfer side. H2Sport Inc. 16 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  17. 17. Using an oven set to 400°F, heat brass install tool (with lobe) until the 350°F temperatureindicator turns color. Be patient - this may take up to 45 minutes. Squares ontemperature strip will turn dark gray when temperature value is reached. DO NOT USE aTORCH to heat brass tool. AN OVEN IS A MUST. H2Sport Inc. 17 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  18. 18. While brass tool is heating, de-grease end of cam with brake clean or acetone.Wipe green loctite onto end of cam.Insert locating tab tool into slot on end of cam. H2Sport Inc. 18 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  19. 19. When temperature strip indicates 350°F, and using thick leather gloves (such as weldinggloves) remove HOT install tool from oven and while holding in one hand orient slothorizontal and lobe pointing down. Quickly, but in a controlled manner,align slot in brass tool with install tab in end of cam then slip fully onto the cam with onesmooth action. Don’t hesitate. Line-up and slip-on fully.Hold in place for 15 seconds to allow cam lobe to cool and shrink onto cam. H2Sport Inc. 19 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  20. 20. Fully installed. H2Sport Inc. 20 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  21. 21. Remove brass install tool. It should slide off. If not insert bolt into end of brass tool andtighten to push-off.Verify new lobe to be flush with end of cam.Wipe away any excess loctite. H2Sport Inc. 21 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  22. 22. Installation Continued:Install modified end-cover (6 perimeter bolts) with supplied new gasket. H2Sport Inc. 22 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  23. 23. Lightly oil O-ring and liberally oil ID on new fuel pump mount and install into end cover. H2Sport Inc. 23 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  24. 24. H2Sport Inc. 24 203 Guelph Street,Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  25. 25. Lubricate roller follower and install into fuel pump mount with anti-rotation tab alignedwith groove. H2Sport Inc. 25 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  26. 26. Carefully pull plunger out of fuel pump with your hands.Pull off stock spring and install new spring in its place. NOTE: WHITE PAINTED ENDGOES TOWARDS FUEL PUMP. H2Sport Inc. 26 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  27. 27. H2Sport Inc. 27 203 Guelph Street,Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  28. 28. Lubricate plunger with engine oil and slip into fuel pump with a rotating motion. H2Sport Inc. 28 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  29. 29. Audi A4’s: Remove 2 tamper proof screws from fuel pump end cover and rotate cover180°. DO NOT REMOVE COVER FROM PUMP. It’s only necessary to rotateit. Insert 2 tamper proof screws and tighten. H2Sport Inc. 29 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  30. 30. Lube fuel pump O-ring with engine oil and install fuel pump into new mount careful notto cut O-ring and secure with new longer bolts. H2Sport Inc. 30 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  31. 31. Install fuel lines to pump. Since pump is moved outwards away from end cover, it willbe necessary to bend fuel lines slightly to fit.Re-shaping fuel lines is best accomplished with the lower securing tab removed. H2Sport Inc. 31 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  32. 32. Reshape lines until they line-up with their respective fittings on the pump. H2Sport Inc. 32 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  33. 33. DO NOT force the fittings onto pump as they will easily cross thread. The fittings shouldeasily thread on by hand. H2Sport Inc. 33 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  34. 34. Audi A4’s: - It will be necessary to bend the low pressure fuel line down to clear steel coolant pipe.- It will be necessary to clearance engine cover mount bracket to clear fuel pump. H2Sport Inc. 34 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  35. 35. Install Schrader valve (if equipped).Connect pressure sensor connector and pressure regulator connector. H2Sport Inc. 35 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  36. 36. Connect Cam Timing Solenoid connector and brackets screws. H2Sport Inc. 36 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com
  37. 37. Connect battery ground.Start engine. May take a few cranks.Check for leaks.Done ☺ H2Sport Inc. 37 203 Guelph Street, Georgetown, Ontario, Canada L7G 4A8 905-702-8299 info@h2sport.com

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