Removal and installation of the high pressure fuel pump
Removing the high pressure fuel pump
1. Place the vehicle on a two post lift.
2. Disconnect the negative battery terminal.
3. Remove the right front wheel from the vehicle.
4. Remove the front section of the right front fender liner.
5. Unscrew the fastening bolts and remove the engine protective tray.
6. Remove attachment drive belt (see chapter "The mechanical part of the diesel engine 1.5 l").
7. Remove the crankshaft pulley (see chapter "The mechanical part of the diesel engine 1.5 l").
8. Remove the lower jet thrust of the engine (see chapter "The mechanical part of the diesel engine 1.5 l").
9. Remove right engine mount (see chapter "The mechanical part of the diesel engine 1.5 l").
10. Remove the camshaft position sensor.
11. Remove the turbocharger outlet duct.
12. Remove the high pressure fuel line between the high pressure fuel pump and the fuel rail (see below).
13. Unhook the latches (1) top cover of the timing gear drive.
14. Loosen the bolt (2) and remove the upper timing cover.
15. Loosen the bolts (3) and remove the bracket for the right engine mount.
16. Loosen the bolt (4) and remove the protection of the high pressure fuel pump.
17. Clean the fuel feed line connector on the high pressure fuel pump.
Caution: Care must be taken to protect surfaces that may be exposed to escaping fuel to avoid corrosion or damage.
18. Disconnect the fuel supply line connector from the high pressure fuel pump (5).
19. Install suitable plugs on the high pressure fuel pump port and fuel feed line.
20.Clean the fuel return line connector on the high pressure fuel pump.
21. Disconnect fuel injector return line from high pressure fuel pump (6).
22. Install suitable plugs on the high pressure fuel pump port and fuel return line.
23. Place the piston of the first cylinder of the engine at top dead center (TDC). Camshaft pulley hole (7) must be opposite the hole in the cylinder head (8).
24.Insert the dowel pin from the kit (Mot. 1430) (9) into the holes of the pulley hub, camshaft and cylinder head.
25.Remove the dowel pin from the kit (Mot. 1430).
2b. Install the high pressure fuel pump retainer (10) on the cylinder head.
Note: If necessary, slowly turn the engine crankshaft until the locking tool is aligned with the teeth of the injection pump pulley.
27. Loosen the nut (11) high pressure fuel pump pulley, securing the pulley from turning with a 32 mm wrench.
Note:
- There are two types of high pressure fuel pump gears. First type of toothed pulley (A) has 6 spokes evenly spaced around the circumference of the pulley. Second type (IN) has 4 knitting needles, unevenly distributed.
- To remove the pulley (A) high pressure fuel pump uses a gear puller for the high pressure fuel pump cone hub (Mot. 1525).
- To remove the pulley (IN) high pressure fuel pump in addition to the puller (Mot. 1525) additional grips are used to remove the high pressure fuel pump pulley (Mot. 1768).
28.Install the puller (Mot. 1525) (12) on the gear pulley of the high pressure fuel pump.
Note: Remove the spacer from the pusher end of the toothed pulley puller (Mot. 1525) to improve positioning on the high pressure fuel pump shaft.
Note: Place additional grips (Mot. 1768) on the spokes of the high pressure fuel pump gear pulley to prevent damage to the pulley spokes.
29. Screw in the puller rod (Mot. 1525) before contact with the high pressure fuel pump shaft.
Note: Make sure the puller rod is (Mot. 1525) correctly oriented and rests against the high pressure fuel pump shaft. If necessary, adjust the position of the puller (Mot. 1525).
30. Loosen the bolts (13) high pressure fuel pump.
31. Gradually screwing the puller rod (Mot. 1525), move the high pressure fuel pump out of place.
Note: When screwing in the puller rod (Mot. 1525) guide and support the high pressure fuel pump with one hand.
32. Remove the high pressure fuel pump.
Note: If the high pressure fuel pump is to be reused, place it in a sealed bag after removal. Remove puller (Mot. 1525) from the high pressure fuel pump.
High pressure fuel pump installation
1. Check for the presence of a key in the high pressure fuel pump shaft.
2. Install the high pressure fuel pump on the cylinder head by inserting it into the toothed pulley.
Note: Make sure that the high pressure fuel pump shaft is correctly positioned in relation to the toothed pulley.
3. Screw on, without tightening, the high pressure fuel pump.
4. Tighten the high pressure fuel pump mounting bolts in the sequence shown in the figure to 23 Nm.
5. Tighten the high pressure fuel pump pulley nut to 70 Nm while holding the pulley from turning with a 32 mm wrench.
Note: Make sure the timing belt is in good condition and installed correctly.
6. Remove the high pressure fuel pump retainer from the cylinder head.
7. Install the bracket for the right engine mount and tighten the mounting bolts in the sequence shown in the figure to a torque of 25 N·m.
8. To establish the top cover of a drive of the gas-distributing mechanism.
9. Tighten the bolt of the top cover of the timing gear.
10. Hook the latches on the top cover of the timing gear.
11. Remove the plugs from the fuel return line of the fuel injectors and the corresponding port of the high pressure fuel pump.
12. Connect the injector fuel return line to the high pressure fuel pump.
13. Remove the plugs from the fuel supply line and the corresponding port of the high pressure fuel pump.
14. Connect the fuel supply line to the high pressure fuel pump.
15. Install the protection of the high pressure fuel pump.
16. Install high pressure fuel line between fuel pump and fuel rail.
17. Install the turbocharger outlet duct.
18. Install the camshaft position sensor.
19. Install right engine mount.
20. Install the lower jet thrust of the engine.
21. Install the crankshaft pulley.
22. Install the attachment drive belt.
23. Install the engine protection tray.
24. Install the front section of the right front fender liner.
25. Install the right front wheel on the car.
26. Connect the battery.
27. Fill the system with fuel using the manual priming pump (with automatic venting).
28. Check for fuel leaks.
29. Using a scan tool, perform post-repair procedures for the injection control unit and high pressure fuel pump.