Attention. Before performing any work on the fuel distribution line, attach a diagnostic tool. establish communication with the injection system control unit and make sure that the fuel distribution line is not under pressure.
Take precautions against possible burns from hot fuel.
Removal
- Disconnect the cable from the negative terminal of the battery
- Remove the air flow sensor
- Remove the air filter housing
- Remove the expansion tank and move it to the side.
- Remove the air duct located between the heat exchanger and the engine stop valve body by disconnecting the fuel line from the pressure switch.
- Remove the reinforcement arm (1. Fig 4.35). connecting the housing of the turbocharger engine stop block with the bracket of the power steering pump
- Remove the exhaust gas recirculation hose as well as the sealing gaskets. When installing the air path, replace the hose and gaskets.
- Disconnect the connector from the EGR control solenoid valve.
- Remove the bolts (3. fig. 4.53) engine stop housing mountings.
Pic. 4.53. Bolt Location (3) engine stop housing mountings
- Remove the pipe (5, fig. 4.38), connecting the throttle assembly to the intake manifold and the intake manifold.
- From the underside of the car, remove the engine stop housing.
- By label (1, fig. 4.2) On the crankshaft pulley, set the engine crankshaft to the TDC position of the piston of the 1st cylinder, unscrew the plug (A. fig. 4.3) and lock Mot. 1536 block the crankshaft from turning.
- Disconnect the pump pressure regulator (RSV), diesel fuel temperature sensor and position sensor.
- Disconnect the fuel return line and the fuel supply line on the pump and install plugs to protect against dirt.
- Remove the expansion tank fastening.
- Disconnect the line protection and move it to the side as far as possible.
- Disconnect the high pressure fuel line at the pump outlet/fuel inlet and install sealing plugs.
- Remove the position sensor (1, fig. 4.54). while being careful not to drop the o-ring into the gear block.
Pic. 4.54. Position sensor location (1) and cap (2) pump hub
- Remove the pump hub cap (2).
- Install the Mot 1548 tool with the centering sleeve, then after installing the tool in place, remove the centering sleeve (pic. 4.55).
Pic. 4.55. Installation of tool Mot. on the engine. 1548 with centering sleeve
- Remove the TDC lock Mot. 1536.
- Using a screwdriver, block the engine flywheel and unscrew the central nut securing the pump hub.
- Unscrew the three bolts securing the pump to the multifunctional bracket a few turns (pic. 4.56).
Pic. 4.56. Location of pump mounting bolts on multifunctional bracket
- By turning the bushing of tool Mot. 1548 remove the pump (pic. 4.55).
- Remove the bolts and high pressure fuel pump.
Installation
- Installation is carried out in sequence. reverse to withdrawal.
- When installing the pump, use the center nut to install the new pump. Be sure to line up the rear pump mounting holes.
- With the Mot. 1503 install the new pump cover (pic. 4.57).
Pic. 4.57. Using tool Mot. 1503 for installing the new pump cover
Do not apply additional force to the high pressure fuel line; to do this:
- loosen the tightening of the fuel distribution line bolts;
- bring the high pressure fuel line nuts on the pump side and the line side closer to each other before tightening them to the required tightening torque;
- tighten the fuel line to the required tightening torque;
- Tighten the nuts on the pump side and the fuel line to the required torque.
Whenever you remove the injection pump, be sure to replace the diesel fuel recirculation fuel line.
Refill the fuel system:
- close the tap (R, fig. 4.52);
- operate the low pressure pump several times with the ignition on;
- start the engine;
- open the tap, and in the open position of the tap the two colored marks are aligned
Using a diagnostic tool, check for stored fault codes and. if present, remove them.
After carrying out any work, check that there are no leaks from the diesel fuel supply circuit. Let the engine idle until the electric cooling fan turns on, then increase the engine speed several times while idling.