B1HG30K1 - 307 DW10TD ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL PUMP (SIEMENS)

IMPERATIVE : when working on the diesel circuit, follow the advice on cleanliness ; if any work is carried out on the high pressure pipes they must always be replaced .

1 - SPECIAL TOOLS

[1] Cross beam (-).0102-D .

[2] Lifting chain (-).0102-M .

[3] - [4] High pressure pump fixing dummy hub (-).0188-AB .

[5] Set of plugs (-).0188-T .

[6] Tightening kit (-).1603-ZZ .

[7] Pulley immobilisation pin (-).0188-V .

2 - REMOVAL

IMPERATIVE : before any repair : wait 30 seconds after the ignition has been switched off .

Disconnect the battery .

Remove the styling cover from the engine .

Move aside :

• the injectors harness (1A)
• the engine harness sheathing (1)
• the priming pump
• the diesel return pipe on the high pressure pump

IMPERATIVE : blank the holes with the caps [5] .

Remove :

• the priming pump bracket (2)
• the engine style cover bracket (3)
• the fuel intake pipe (6)

IMPERATIVE : blank the holes with the caps [5] ; clean the high pressure unions before slackening .

Unscrew :

• the connector (8), keeping the connector on the pump (A) using an open ended spanner.
• the pipe (9)

Remove :

• the diesel supply tube (7)

IMPERATIVE : blank the holes with the caps [5] .

Remove :

• the 3 bolts (10) and their washers
• the rear bracket (11) for the high pressure pump

WARNING : take care not to lose the high pressure pump rear fixing .

Support the engine with a carrier and the tools [1] and [2] by the lifting hook .

Remove the right-hand engine mounting .

Remove :

• the top front timing case (5)
• the nut (4) (using the tool [7])

Position the tools [3] - [4] .

Tighten :

• the bolts of tool [3] to 4.0 dan.m
• the bolts of tool [4] to 1.5 dan.m

Remove :

• the bolts (13) and the nut (14)
• the diesel high pressure pump by tightening the bolt (12)

3 - REFITTING

Remove the tool [4] .

Position the diesel high pressure pump .

Tighten :

• the bolts (13) to 2.3 da.Nm
• the nut (14) to 2.3 da.Nm
• the nut (4) by hand

IMPERATIVE : if any work is carried out on the high pressure pipes they must always be replaced .

Position the diesel supply tube (7) .

Tighten the unions (8) - (9) by hand (In order) .

Pre-tighten the connections (9) - (8) to 2.4 dan.m .

Tighten :

• the union (9) to 2.8 daN.m
• the union (8) to 2.5 daN.m

Continue the fitting operations in the reverse order to removal .

Tightening torques :

• bolt(s) (10) to 2.3 m.daN
• nut (4) to 5.0 m.daN
• high pressure pump fixing stud on bracket to 6.5 dan.m
• bolt on the engine bracket to 6.0 dan.m

Re-prime the diesel circuit using the priming pump .

Initialise the various ECUs .

3 - 1 - LEAKAGE CHECK

Start the engine .

Check that there are no fuel leaks .