B1HG1WK1 - 607 DW12TED4 ENGINE

REMOVAL - REFITTING HIGH PRESSURE FUEL PUMP

IMPERATIVE : when carrying out an operation on the diesel circuit, respect safety instructions .

WARNING : 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] Pulley immobilisation pin (-).0188-V .

[4] Assembly for detaching the high pressure pump pinion (-).0188-R .

[5] Pipe spanner (-).1603-G ( 4220-TD) .

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

[7] Tightening kit (-).1603-A/E/B/D ( 4220-T (B-J)) .

2 - REMOVAL

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the timing belt .

Refit the engine upper mounting .

Slightly tighten the bolts .

Disconnect and move aside the electric harness .

Move aside : The harness bracket (1) .

Disconnect the connectors .

Drain and move aside the filter element reservoir (2) .

Plug the holes using tool [6] .

Remove the filter element reservoir support (3) .

Slacken the nut (4) (Using the tool [3]) .

Remove :

• high pressure pump drive pulley (5) (using the tool [4])

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The dipstick tube mounting bolt (15) .

ALL MODELS

IMPERATIVE : clean the fuel unions before slackening .

IMPERATIVE : apply a counter-torque at (A) .

Move aside : The hoses (10) and (11) .

Plug the holes using tool [6] .

Remove :

• high pressure pipes (6)
• the bolts (7)

Slacken the bolt (13) .

Tilt the bracket (14) .

Remove the fastenings (12) .

Remove the high pressure fuel pump .

3 - REFITTING

Always renew : The high pressure pipe (6) .

Proceed in the reverse order to removal .

Tighten :

• the fastenings (12) to 2.25 da.Nm
• the bolts (7), (13) to 2,25 da.Nm
• finger tighten : the hoses (A)
• the nut (4) to 5 da.Nm

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refit the timing belt .

Fit : The high pressure supply pipe; Tighten the unions by hand .

Tighten : The pipe (6), Tightening torque: 2,25 da.Nm (Using tools [5] and [7]) .

Carry out a road test :

• engage 3rd gear, stabilise the engine speed at 1000 rpm
• accelerate fully (up to 3500 rpm)

Check all the pipes for leaks .