Note.
- Necessary special devices, control and measuring devices, as well as auxiliary means:
- Retaining lever -T10051-.
- Puller -T40064-.
- Driving device -T40064/1-.
- Pins -740064/2-.
Removing
Note. When working on the power supply system, safety precautions must be observed.
1. Remove the timing belt and high pressure fuel pump (for details, see the relevant section in chapter diesel engine).
Attention.
- The plugs must be disconnected from the spark plugs carefully.
- If the plug is damaged during disconnection, the entire wiring harness, including the plugs, would have to be replaced (plugs cannot be replaced individually).
2. Carefully disconnect the wiring harness connectors from the glow plugs as shown in the figure below. It is possible to facilitate the work with a 12 mm open-end wrench.
3. Remove fixing screws (arrows), shown in the figure below, then set the coolant return pipe aside as shown in the figure below.
4. Unscrew the support screws (arrows), shown in the figure below.
5. Disconnect the fuel supply line (arrow) on the high pressure pump and disconnect the wiring harness connector (1) fuel temperature sender -G81- as illustrated below.
6. Unscrew the fastening screws (1), (3), (4), remove the engine support bracket (grey), as shown in the figure below.
7. Disconnect the fuel return line (2), shown in the figure below.
8. Remove the high pressure fuel line between the high pressure pump and the fuel dispenser.
9. Remove the toothed drive belt pulley from the high pressure pump.
10. Hold the hub of the high-pressure pump with counterhold -T10051- and unscrew the lock nut (1), shown in the figure below.
Note. For puller -T40064-, replace main stop with stop -T40064/1-.
11. Fit puller -T40064- with pressure piece -T40064/1- and pins -T40064/2- as shown in the figure below, then remove the hub from the high pressure pump. If necessary, stick with a 24 mm open-end wrench.
12. Remove fixing screws (arrows) high pressure pump as shown in the figure below.
13. Remove the high pressure pump.
Installation
Attention.
- Risk of damage to the high-pressure pump due to dry running.
- If the high pressure fuel pump has been removed or replaced, the high pressure fuel pump must be filled with fuel before the engine is started for the first time. To do this, connect the diagnosis, measuring and information system -VAS 505x- and carry out the function "Removing air from the power system". The fuel pump is only active for 180 seconds at this time.
Note. When installing a new high pressure pump, care must be taken to ensure that no contamination enters the supply system. The plugs should only be removed before installing the fuel lines.
1. Installation is carried out in the reverse order of operations, and the following instructions must be observed:
The high pressure pump screws must be replaced.
Note. If the high pressure pump is replaced, the stored values must be reset.
2. Fill the system and remove air from the supply system. To do this, connect the diagnostic, measuring and information system -VAS 505x- and carry out the function "Venting the supply system. The fuel pump is only active for 180 seconds at this time.
3. Check the tightness of the power system.