Exploded View

1. High pressure supply pump protector 2. High pressure supply pump

: N·m (kg-m, ft-lb)

Removal and Installation

REMOVAL

CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-263, "Precaution for Diesel Equipment".

• Wait until the fuel temperature drops before carrying out any work.

• Order the special high pressure injection circuit plug kit.

• In case of the replacement of the high pressure supply pump sprocket, please apply the following tightening torque:

: 70.0 N·m (7.1 kg-m, 52 ft-lb)

1. Disconnect the battery cable from the negative terminal.

2. Remove cowl top extension. Refer to EXT-20, "Exploded View".

3. Remove turbocharger air inlet pipe. Refer to EM-280, "Exploded View".

4. Remove air inlet tube assembly and air inlet tube. Refer to EM-281, "Exploded View".

5. Remove the timing belt. Refer to EM-302, "Exploded View".

6. Remove the neck located on the fuel rail, 7. Remove the oil level gauge guide and plug the hole.

8. Remove high pressure protection cover. Refer to EM-294, "Exploded View".

9. Carefully disconnect:

• The connectors from the flow actuator, • The connectors from the fuel temperature sensor, • On the pump, the fuel supply and return pipes.

• The return pipe connecting the injectors with the pump.

10. Remove the injection tube connecting the pump to the rail. Refer to EM-294, "Exploded View".

11. Plug all the holes of the injection circuit.

12. Remove the three mounting bolts from the high pressure supply pump then remove it.

INSTALLATION

1. Install the pump then position the mounting bolts without tightening them.

2. Before fitting the new injection tube, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit.

3. Refit the injection tube, to do this:

• remove the protective plugs, • insert the injection tube olive into the taper of the high pressure pump outlet,
• insert the injection tube olive into the taper of the high pressure rail inlet.

4. Finger tighten the nuts of the injection tube starting with the one located on the rail side.

5. Tighten the mounting bolts on the high pressure pump.

: 21.0 N·m (2.1 kg-m, 15 ft-lb)

6. Tighten the injection tube nut.

: 24.0 N·m (2.4 kg-m, 18 ft-lb)

7. Refit high pressure supply pump protector.

CAUTION:
When refitting high pressure supply pump protector, follow steps below.

• Tighten bolt with holding protector towards to high pressure supply pump.

:21.0 N·m (2.1 kg-m, 15 ft-lb)

• Make sure disk rubber (1) is touching with bolt head of high pressure supply pump (2).

8. Refit in the reverse order to removal for the other refitting operations.

9. Test the sealing of the high pressure after it has been repaired (refer to “SPECIAL FEATURES” in EM- 263, "Precaution for Diesel Equipment").