Contents: Removal ↳ Installation ↳
Caution: Be careful not to get any dirt into the feed pump or injector lines during this procedure. When reinstalling, new O-rings must be used on the fuel line connections.
Removal
1. Disconnect the negative battery cable.
2. On 1995 models, disconnect the heater from the coolant expansion tank, then remove the two retaining bolts and set the tank aside.
3. Contact Chapter 2A and remove the timing belt.
4. Unscrew the bolts of the high pressure fuel pump toothed pulley, then remove the disc and pulley (see Figure 7.4, a-c).
Figure 7.4a. Unscrew the fuel pump toothed pulley bolts.
Figure 7.4b.... remove the plate...
Figure 7.4c.... and toothed pulley.
5. Remove the air filter as described in section 3 if necessary, to improve access to the fuel pump.
6. Cover the starter with a plastic bag to protect it from fuel spills.
7. Disconnect the fuel delivery line from the high pressure pump. Remove the copper washers from the banjo connection. Cap the open end of the fuel line and install it, then cap the banjo bolt to protect it from contamination.
8. Disconnect the main fuel return line and, where fitted, the injector return line banjo connection (see Figure 7.8). Remove the copper washers from the banjo fitting. Close the open end of the pipe and install it, then close the banjo bolt to protect it from contamination.
Figure 7.8. Disconnect the injector drain line banjo connection.
9. Disconnect all wires from the pump. Please note that on some Bosch pumps this may require simply disconnecting the plug connector. On some other pumps, it is necessary to disconnect the wires from individual components, and some of the connections may be protected by rubber sheaths. On turbocharged models with the Lucas EPIC control system, disconnect the large multi-pin mounting plug from the receptacle on the rear of the pump. Seal any open areas in the pump after disconnecting.
10. Unscrew the union nuts securing the injector tubes to the high-pressure fuel pump and injectors. Hold the connections on the pump while loosening the nuts that connect the discharge tubes to the pump. Remove all the tubes together. Seal open joints using small plastic bags or the fingers from old ones (but clean!) rubber gloves (see Figure 7.10).
Figure 7.10. Cover all disconnected connections with the fingers of an old rubber glove or with small bags.
11. Disconnect the accelerator cable from the high-pressure fuel pump, referring to the section.
13. On engines with an EGR system, disconnect the EGP valve rail (see Figure 7.11).
Figure 7.11. Disconnect the EGR valve control lever.
12. If necessary, disconnect the idle speed control cable from the high pressure fuel pump by referring to section 5.
13. Unscrew the bolts and remove the rear fuel pump support bracket (see Figure 7.13).
Figure 7.13. Remove the fuel pump rear support bracket bolts (shown by arrows).
14. While supporting the fuel pump, remove the front mounting nuts or bolts. Remove the pump from the engine, supporting it slightly (see figure 7.14,a,b).
Figure 7.14a. Unscrew the front fixing bolts.
Figure 7.14b....and remove the fuel pump by lifting it.
Installation
15. Begin reinstalling the fuel pump by installing the rear support bracket onto the pump.
16. With the pump positioned on the engine, install the mounting nuts and bolts, tightening them to the specified torque. Make sure the rear support bracket does not interfere with the installation.
17. Connect the fuel injection and drain hoses and tighten their connections. Use new copper washers on banjo connections.
18. Install and connect the fuel injector pipes.
19. Attach the rear fuel pump support bracket to the cylinder block and tighten the connecting bolts to the specified torque.
20. Connect all necessary wires to the pump.
21. Install the high pressure fuel pump sprocket and disc. Make sure the locking bolts are in the center of the pulley slots.
22. Install and adjust the timing belt as described in Chapter 2A, section 7.
23. Connect the idle speed control cable to the high pressure fuel pump by referring to section 5.
24. Connect the accelerator cable to the high-pressure fuel pump, referring to section 13.
25. Install the air filter if it was removed by referring to section 3.
26. Connect the negative battery cable.
27. Remove the plastic bag from the starter.
28. Remove air from the fuel system as described in section 2.
29. Start the engine and check the fuel pump adjustment.