Caution: After disconnecting the fuel lines, plug the exposed holes to prevent dirt from entering the fuel supply system.
Engine 3.6 l
1. Relieve fuel pressure (see Section 3).
2. Remove the bolts (see resist. illustration) and remove the air intake.
10.2 Air intake bolts
3. Loosen the bolts and remove the lifting eye (And on the opposite illustrations).
10.3 Fixing the lifting eye
4. Disconnect the connector (arrow on resist illustrations) sensor "G247" fuel pressure, disconnect the low fuel pressure hose (1) and remove the high pressure line (2), while holding the injection pump connection with the key.
10.4 Injection pump connections
5. Disconnect the connector (1 per resist. illustrations), remove the bolts (arrows) and remove the injection pump (IN). Check the integrity of the injection pump rod and, if necessary, replace it.
10.5 Fasteners for injection pump
6. Insert lubricated stem (1 per resist. illustrations) injection pump and steer to the correct position (2) in the cylinder head. While pushing the rod in the direction of the arrow, slowly turn the crankshaft by the pulley until the rod is as deep as possible. Further installation is carried out in the reverse order. Use a new injection pump O-ring.
10.6 Installing the injection pump rod
Engines 1.4 l
7. Details of the installation of the high-pressure fuel pump are indicated on the resist. illustrations. Removal and installation of high pressure fuel pump are carried out by analogy with the 3.6 l engine (see above).
10.7 1.4 l engine injection pump installation details
1 Bolts, 15 Nm
2 Hose fitting 4
3 Spring band clamp
4 Low pressure fuel hose, with clamp 3
5 Union nut, 18 Nm
6 Connection, replaceable, 30 Nm
7 injection pump with valve "N276" fuel pressure adjustment
8 Roller tappet, lubricate with engine oil before installation
9 O-ring, to be replaced, lubricate with engine oil before installation
Petrol engines 1.8 and 2.0 l
8. Details of the installation of the high-pressure fuel pump and other parts involved in its operation are indicated on Ref. illustrations.
10.8 High pressure pump installation details (petrol models 1.8 and 2.0 l)
1 roller pusher
2 O-ring, to be replaced
3 injection pump with valve 4; the high pressure pipe is attached to the injection pump with a force of 17 Nm
4 valve "N276" fuel pressure adjustment
5 Place in the vacuum pump for the installation of high pressure fuel pump
6 Injectors
7 CMP sensor "G40"
8 Valve #1 "N205" camshaft phase adjustment
9 High pressure pump bolts, to be replaced, 10 Nm
10 Hose fitting from the fuel tank
11 Pressure tube connection, replaceable, 22 Nm (the tube is attached with a force of 18 Nm)
9. Relieve fuel pressure (see Section 3).
10. Turn the crankshaft so that the risk on its pulley matches the mark "TDC" on the timing cover (see Figure 25.5 Chapter 2).
11. Disconnect the connector (1 per resist. illustrations) sensor "N276" fuel pressure adjustment.
10.11 Valve connector "N276" and fasteners for injection pump
12. Disconnect the supply hose from the injection pump (upper arrow on resist. illustrations) and pressure fuel line (bottom arrow).
10.12 Fuel lines on injection pump
13. Turn out bolts (arrows in illustration 10.11) and carefully pull out the injection pump. In some cases, the injection pump pusher may remain in the cylinder head, in which case it must be removed separately.
14. Remove the old O-ring from the injection pump. Lubricate the new O-ring with engine oil and install it on the injection pump groove.
15. Turn the crankshaft so that the plunger with the roller is at its deepest point. Insert the injection pump into the vacuum pump and hand-tighten the injection pump bolts.
16. Further installation is carried out in reverse order.
Diesel engines 2.0 l (CFHC, CFJA and CLCB)
17. Details of the installation of the high-pressure fuel pump are indicated on the resist. illustrations.
10.17 Details of installation of injection pump for diesel engines 2.0 l (CFFB, CFGB and CLJA)
1 Auxiliary bracket
2 Bolt, to be replaced, 20 Nm, then retighten 180°
3 Hub
4 Injection pump gear
5 Bolt, to be replaced, 20 Nm, then retighten 90°
6 Nut, 95 Nm
7 Bolt, to be replaced, 20 Nm, then retighten by 45°
8 injection pump with valve "N290" fuel dosing
9 Fuel supply hose
10 Fuel return hose
11 Fuel pressure line between injection pump and fuel rail, 15 Nm, then tighten 60°
Attention: After removing the components of the fuel supply system, before starting the engine, the air must be bled from the system (see Section 3).