1. Preparation is Key:
* Identify the Correct Location: This is absolutely crucial. You need a precise location to avoid drilling into a critical area of the block. Consult a reliable engine machine shop manual or a reputable online resource specifically for your engine's year and model. The manual will show you exactly where to drill. Using a template designed for this purpose is highly recommended.
* Clean the Block: Thoroughly clean the area where you'll be drilling. Remove any dirt, grease, or debris that could interfere with the drilling process or damage the drill bit.
* Secure the Block: The block must be securely clamped to a sturdy workbench to prevent movement during drilling. This is essential to ensure accuracy.
* Choose the Right Drill Bit: Use a drill bit that matches the exact diameter of your fuel pump pushrod. Using a bit that's too large will create slop, and too small will not allow for proper pushrod function and may even damage the pushrod. A high-quality drill bit is strongly recommended.
* Pilot Hole (If Necessary): Some methods recommend starting with a smaller pilot hole before drilling to the final size. This helps guide the larger bit and minimizes the chance of the bit wandering.
2. Drilling the Hole:
* Start Slow: Begin drilling at a low speed with light pressure. This allows the drill bit to center itself and prevents it from walking or slipping.
* Lubrication: Use cutting oil or a suitable lubricant to keep the drill bit cool and lubricated. This extends the life of the bit and helps prevent the bit from binding or overheating.
* Maintain Even Pressure: Apply consistent, even pressure as you drill. Avoid applying too much pressure, which could break the drill bit or damage the block.
* Multiple Passes: It's often better to make several passes with the drill bit, increasing the pressure slightly with each pass, rather than trying to drill through in one go. This will help maintain accuracy and avoid breakage.
* Regularly Check Alignment: Periodically stop drilling and inspect the hole to ensure it remains centered and straight.
3. Finishing:
* Deburr: After drilling, deburr the hole to remove any sharp edges. This will prevent damage to the pushrod. A deburring tool or a small file can be used.
* Inspection: Carefully inspect the hole to ensure it's the correct size and is straight and true.
Important Considerations:
* Professional Help: If you're not comfortable performing this task yourself, it's highly recommended that you take your engine block to a professional machine shop. Drilling this hole incorrectly can cause serious engine damage. They have the tools, experience, and jigs to do this perfectly.
* Block Material: The drilling process might vary slightly depending on the specific material of your engine block.
* Safety First: Always wear appropriate safety glasses and hearing protection when drilling.
This procedure is a guideline. Always refer to the specifications for your specific engine and consult reliable sources before attempting this repair. A mistake here can be costly.
