What Does The Engine Malfunction Reduced Power Message Mean For Your BMW X5
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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 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.
H2Sport Inc. 1
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
2. 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.
H2Sport Inc. 2
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
3. 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.
H2Sport Inc. 3
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
4. Basic Installation Instructions - Cam in
Car:
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.
H2Sport Inc. 4
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
5. Disconnect connector to cam adjuster solenoid. Unclip harness clamp and set harness off
to the side. Remove 2 bracket screws.
H2Sport Inc. 5
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
6. 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.
H2Sport Inc. 6
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
7. 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.
H2Sport Inc. 7
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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. 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.
H2Sport Inc. 10
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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
13. 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.
H2Sport Inc. 13
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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. 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
H2Sport Inc. 15
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
16. 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.
H2Sport Inc. 16
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
17. 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.
H2Sport Inc. 17
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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. 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.
H2Sport Inc. 19
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
21. 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.
H2Sport Inc. 21
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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. 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
25. Lubricate roller follower and install into fuel pump mount with anti-rotation tab aligned
with groove.
H2Sport Inc. 25
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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 END
GOES TOWARDS FUEL PUMP.
H2Sport Inc. 26
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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. 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.
H2Sport Inc. 29
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
30. 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.
H2Sport Inc. 30
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
31. 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.
H2Sport Inc. 31
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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. DO NOT force the fittings onto pump as they will easily cross thread. The fittings should
easily thread on by hand.
H2Sport Inc. 33
203 Guelph Street,
Georgetown, Ontario, Canada
L7G 4A8
905-702-8299
info@h2sport.com
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
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
