High pressure fuel pump (Renault Espace III)

It is not recommended to disassemble the high pressure fuel pump.

Caution: Before carrying out any work on the fuel rail, connect the diagnostic tool to the injection system control unit and ensure that the fuel rail 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 set it aside.
• Remove the air duct located between the heat exchanger and the engine stop valve housing by disconnecting the fuel line from the pressure switch.
• Remove the reinforcement paw (1. Fig. 4.35). connecting the turbocharger engine stop block housing with the power steering pump bracket
• Remove the EGR hose and sealing gaskets. Replace the hose and gaskets when installing the air duct.
• Disconnect the connector from the EGR control solenoid valve.
• Remove the bolts (3. Fig. 4.53) engine stop housing fastenings.

• Remove the pipe (5, Fig. 4.38), connecting the throttle body to the intake manifold and the intake manifold.
• From the bottom of the vehicle, remove the engine stop housing.
• By tag (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 using the Mot. 1536 lock, 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 at the pump and install plugs to prevent dirt from entering.
• Remove the expansion tank mount.
• Disconnect the line guard and move it to the side as far as possible.
• Disconnect the high pressure fuel line at the pump outlet/fuel rail inlet and install sealed plugs.
• Remove the position sensor (1, Fig. 4.54). while trying not to drop the sealing ring into the gear block.

• Remove the pump hub cap (2).
• Fit the Mot 1548 tool with the centring sleeve, then once the tool is in place, remove the centring sleeve (Fig. 4.55).

• Remove TDC locking tool Mot. 1536.
• Using a screwdriver, lock the engine flywheel and unscrew the central nut securing the pump hub.
• Loosen the three pump mounting bolts on the multifunctional bracket a few turns (Fig. 4.56).

• Turn the sleeve of tool Mot. 1548 to remove the pump (Fig. 4.55).
• Remove the bolts and high pressure fuel pump.

Installation

• Installation is carried out in the reverse order of removal.
• When installing the pump, use the center nut to install the new pump. Be sure to align the holes of the rear pump mount.
• Using tool Mot. 1503, install the cover of the new pump (Fig. 4.57).

Do not apply additional force to the high pressure fuel line, to do this:

• loosen the fuel rail mounting bolts;
• bring the high pressure fuel line nuts on the pump and line side close together before tightening them to the specified torque;
• tighten the fuel line to the specified torque;
• tighten the nuts on the pump side and the fuel line side to the required tightening torque.

Each time the injection pump is removed, be sure to replace the diesel fuel recirculation line.

Perform a fuel system refill:

• close the tap (R, Fig. 4.52);
• run the low pressure pump several times with the ignition on;
• start the engine;
• open the tap, while in the open position of the tap the two colored marks are aligned

Use a diagnostic tool to check for recorded fault codes in the memory and, if present, delete them.

After performing any work, make sure that there are no leaks from the diesel fuel supply circuit. Allow the engine to idle until the electric cooling fan is turned on, and then increase the engine's crankshaft speed several times while idling.