leva_bomba_gasolina

H2Sport Inc. 203 Guelph Street,

Georgetown, Ontario, Canada L7G 4A8

905-702-8299 info@h2sport.com

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 and worry 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 Contents

New Roller Cam Follower – to replace the stock flat face follower New Cam Lobe with revised contour – for proper fuel pump operation with new follower New Fuel Pump Mount – to fit larger roller follower New Fuel Pump Return Spring – for proper follower/cam dynamics Modified End Cover – to fit new Fuel Pump Mount Optional: New ‘B’ Spec camshaft If your car has an ‘A’ spec cam you’ll need to send it to us for modification.

The Process Read 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 need to 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 which results in less down time for the upgrade but you don’t get your original cover back.

The original cam lobe (arrow) must be remove and replaced with H2Sport’s new revised lobe.

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.

Basic Installation Instructions - Cam in

Disassembly:

NOTE: You will be working with open fuel lines and fuel vapours will be present. No open 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.

Disconnect connector to cam adjuster solenoid. Unclip harness clamp and set harness off to the side. Remove 2 bracket screws.

Relieve fuel pressure at Schrader valve if equipped. If not, crack fuel pressure sensor loose 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.

Completely disconnect fuel lines from fuel pump. Image below shows fuel line connected with banjo bolt. Newer versions use a short rubber hose secured with spring clamps. Cover open fuel line ends with clean shop rags.

Remove Fuel Pump. Set aside in clean area and cover with clean shop rags.

Remove vacuum pump: 3 screws.

Remove End Cover – 6 perimeter bolts - and the various cable brackets attached to it. Some oil will drain out – collect with shop rags.

Locate dimple on intake cam sprocket. Turn crankshaft clockwise until dimple points towards exhaust cam and slot is roughly horizontal. In this position, one lobe of the cam should point down.

Install puller onto cam lobe with arm pointing up, careful of the plastic chain guides.

Tighten bolt on puller to pull the cam lobe off the cam. Counter hold puller to prevent cam from rotating else you risk damaging the plastic chain guides.

With lobe removed, lightly clean the end of cam with scotch brite.

Assembly:

End of cam will feature a slight stepped diameter. Measure the larger diameter (which is closest to the sprocket and is about ¼” wide) with a metric micrometer accurate to 0.01mm.

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 to Ø30.35mm

Choose the closest sized cam lobe - without going over - from kit and insert it into brass install tool with chamfer facing up. White paint marks indicate chamfer side.

Using an oven set to 400°F, heat brass install tool (with lobe) until the 350°F temperature indicator turns color. Be patient - this may take up to 45 minutes. Squares on temperature strip will turn dark gray when temperature value is reached. DO NOT USE a TORCH to heat brass tool. AN OVEN IS A MUST.

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.

When temperature strip indicates 350°F, and using thick leather gloves (such as welding gloves) remove HOT install tool from oven and while holding in one hand orient slot horizontal 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 one smooth 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.

Fully installed.

Remove brass install tool. It should slide off. If not insert bolt into end of brass tool and tighten to push-off. Verify new lobe to be flush with end of cam. Wipe away any excess loctite.

Installation Continued:

Install modified end-cover (6 perimeter bolts) with supplied new gasket.

Lightly oil O-ring and liberally oil ID on new fuel pump mount and install into end cover.

Lubricate roller follower and install into fuel pump mount with anti-rotation tab aligned with groove.

Carefully pull plunger out of fuel pump with your hands. Pull off stock spring and install new spring in its place. NOTE: WHITE PAINTED END GOES TOWARDS FUEL PUMP.

Lubricate plunger with engine oil and slip into fuel pump with a rotating motion.

Audi A4’s: Remove 2 tamper proof screws from fuel pump end cover and rotate cover

180°. DO NOT REMOVE COVER FROM PUMP. It’s only necessary to rotate it. Insert 2 tamper proof screws and tighten.

Lube fuel pump O-ring with engine oil and install fuel pump into new mount careful not to cut O-ring and secure with new longer bolts.

Install fuel lines to pump. Since pump is moved outwards away from end cover, it will be necessary to bend fuel lines slightly to fit. Re-shaping fuel lines is best accomplished with the lower securing tab removed.

Reshape lines until they line-up with their respective fittings on the pump.

DO NOT force the fittings onto pump as they will easily cross thread. The fittings should easily thread on by hand.

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.

Install Schrader valve (if equipped). Connect pressure sensor connector and pressure regulator connector.

Connect Cam Timing Solenoid connector and brackets screws.

Connect battery ground. Start engine. May take a few cranks. Check for leaks. Done ☺

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