Fuel system of diesel engines Two diesel fuel injection systems are used. The 1.9 liter engines are equipped with the Bosch AS3 semi-electronic system, while the 2.1 liter engines are equipped with the complete Lucas EPIC engine management system...
Fuel System Specifications High pressure fuel pumps 1.9 liter engine (DHX) Bosch AS3 VP20 2.1 liter engine (P8C) Lucas/ PSA EPIC Direction of rotation of the fuel pump Clockwise as viewed from drive end Installing a Bosch pump when installing the...
Filling and bleeding the fuel system Manual priming pump After any disconnection of the fuel system, air can enter it and must be removed. In the case of complete depletion of fuel from the fuel tank, it is not necessary to completely fill the fuel tank...
Air filter and air inlets Removing Air filter 1. Loosen the clamps and remove the intake port from the air filter housing. 2. On 1.9 liter engines, disconnect the accelerator cable from the air filter cover. On 2.1 liter engines, remove the...
Accelerator cable — removal, installation and adjustment Removing 1. On 1.9 liter engines, remove the accelerator cable from the high pressure fuel pump control lever (indicated by an arrow). Remove the accelerator cable sheath from the sealing ring installed in the fuel pump...
Accelerator pedal — removal and installation Removing 1. Remove the accelerator cable from the accelerator pedal. 2. Depending on the design, unscrew the hub screws or unscrew the nut from the end of the pedal pivot shaft. 3. Remove a pedal or take a pedal in...
High pressure fuel pump adjustment Control Lever Adjustments B. Idle adjustment screw C. Fuel metering screw Attention! This adjustment only applies to the Bosch fuel pump. The Lucas fuel pump does not need to be adjusted. controlled by the ECU. Because...
Engine stop solenoid valve Attention! When removing the valve, be careful not to get dirt into the fuel pump. Attention! The described operation applies only to the Bosch fuel pump. The engine stop solenoid valve is located at the end of the high...
Bosch high pressure fuel pump — removal and installation Attention! Be careful not to get dirt into the fuel pump or high pressure pipe when working on the fuel pump. Also, always use a new seal. Removing 1. Disconnect the negative battery terminal. 2. Remove the air intake...
High pressure fuel pump Lucas — removal and installation Attention! Be careful not to get dirt into the fuel pump or high pressure pipe when working on the fuel pump. Also, always use a new seal. Removing 1. Disconnect the negative battery terminal. 2. Remove the electronic...
Setting the injection timing The injection timing must be set after the position of the fuel pump has been changed. Equipment for dynamic injection timing, based on the conversion of a pressure pulse in the injector pipe into an electrical signal,...
Setting the injection timing on the Bosch injection pump Dial gauge with adapter mounted on a Bosch fuel pump Attention! To carry out the check and adjustment, it is necessary to use a dial indicator and Peugeot No. 0117AK adapter. 1. If pump injection timing is being tested...
Setting the injection timing on the Lucas injection pump Attention! Be careful not to get dirt into the fuel pump or high pressure pipe when working on the fuel pump. Also, always use a new seal. Removing 1. Disconnect the negative battery terminal. 2. Remove the electronic...
Fuel injectors — removal, inspection and installation Attention! When checking the operation of the fuel injectors, never place your hands or any part of your body under the jet of fuel coming out of the injector. The fuel exits the nozzle at high pressure and can enter...
Sensors and actuators of the Bosch AS3 system Electronic control device (ECU) It is the main component of the system, controlling the injection timing, increased idle speed, glow plugs, and the exhaust gas reburning system. The ECU receives signals from sensors...
Sensors and Actuators (Lucas EPIC) ECU The ECU is the main unit of the engine management system. It controls the fuel injection system and emission control systems. The ECU receives signals from sensors that monitor changing engine operating conditions...
Intake manifold — removal and installation 1.9 liter engines Attention! The intake and exhaust manifolds are mounted on the same gasket. Therefore, it is recommended to remove both manifolds at the same time so that the gasket can be replaced. Removing 1....
Exhaust manifold — removal and installation Removing 1.9 liter engines 1. Remove the intake manifold. 2. Remove the turbocharger. 3. On some models, remove the bolt from the exhaust manifold flange. 4. Remove the six exhaust manifold nuts. 5. Remove the exhaust...
Turbocharger — description and precautions The turbocharger is installed on all diesel engines. It increases engine power by increasing the pressure in the intake manifold above atmospheric pressure. The turbocharger is driven by exhaust gases. The exhaust gas,...
Removal and installation of a turbocharger Attention! On 1.9 liter engines, the turbocharger can be removed from the engine installed on the vehicle. On 2.1 liter engines, due to limited space, the turbocharger can only be removed from the engine removed from...
Turbocharger check The turbocharger cannot be repaired and is replaced as a complete unit. 1. With the turbocharger removed, inspect the turbocharger housing for cracks or other damage. 2. Turn the turbine at maximum speed and check that...
Intercooler — removal and installation The intercooler is located in front of the radiator. Removing 1. Remove the radiator from the cooling system. 2. Remove the air hoses from the intercooler and remove it. Installation Installation is made in sequence,...