Warning. Be careful when performing this procedure to ensure that no dirt enters the high pressure fuel pump or fuel injector lines.
Models with 1.9L engine
Note. If the high pressure fuel pump is being sent to an injection technician for repair, unlock the immobilizer module as described below before disconnecting the battery. Turn on the ignition and open the window on the driver's door. Exit the vehicle and close all doors, then turn off the ignition. Reaching through the window, turn the ignition back on, wait at least 10 seconds. and then turn off the ignition. Disconnect the ground wire from the battery immediately (see «Disconnecting the battery») and disconnect the electrical connectors on the high pressure fuel pump (the pump must be disconnected within 10 minutes after the ignition is switched off). If the immobilizer module is not unlocked, the pump repair technician will not be able to test the pump.
Removing
1. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
2. Release the fasteners on the right side and top plane of the engine cover, and then carefully, so as not to lose the rubber feet, remove the cover (pic. 3.1, a-c).
3. Remove the intake air line connecting the air filter to the EGR valve body (see paragraph 3).
4. Cover the items under the high pressure fuel pump with a plastic bag as a precaution in case of fuel spillage.
5. Remove the high pressure fuel pump sprocket as described in paragraph 9 of chapter 2B.
6. Remove the top section of the intake manifold (see paragraph 17).
7. Disconnect the accelerator cable from the high pressure fuel pump (see paragraph 4).
8. Disconnect the high idle cable from the high pressure fuel pump (see paragraph 10).
9. Follow the high pressure fuel pump feed line to the filter. Wipe the line fitting clean, then loosen and disconnect the line from the filter. Plug the end of the line and fitting on the filter housing to minimize fuel leakage and prevent dirt from entering the system.
10. Wipe clean the area around the high pressure fuel pump metal return line fittings. Disconnect the return line and hose from the metal line and plug the ends of the line and fitting to minimize fuel leakage and prevent dirt from entering the system.
11. Disconnect the high pressure fuel pump electrical connectors (pic. 13.11).
Pic. 13.11. Disconnect electrical connectors (marked with arrows) on the back of the high pressure pump (late models with 1.9 l engine)
12. Remove all traces of dirt from the union connections of all injector fuel lines. Loosen the union nuts securing the fuel lines of the injectors to the high pressure fuel pump and injectors. Hold the fittings on the pump while unscrewing the union nuts securing the lines to the pump. Remove the fuel lines as a set. Plug the injector/high pressure fuel pump fittings to prevent dirt from entering.
13. Release a back bolt of fastening of the pump.
14. Remove the three front bolts securing the pump to the support bracket, and then move the pump out of its original position.
15. If necessary, remove the pump support bracket bolt and remove it from the cylinder head, being careful not to lose the dowel pins.
Installation
16. If necessary, replace the dowel pins and install the support bracket on the cylinder head. Tighten the bracket mounting bolts to the specified torque.
17. Properly install the rear pump mounting bolt, spacer, washer, and nut to the support bracket.
18. Install the pump in its original place and properly position it in the support bracket.
19. Screw in the front pump mounting bolts and tighten them to the prescribed torque. After tightening the front bolts, tighten the rear bolt to the specified torque.
20. Install and connect fuel injector lines. Pre-tighten all union nuts to ensure that all fuel lines are correctly positioned, then tighten them to the specified torque in the same sequence. Hold the fittings on the high pressure fuel pump while tightening the nuts on the pump side.
21. Connect the appropriate electrical connectors on the pump.
22. Securely connect the supply and return lines to the high pressure fuel pump and to the fuel filter housing.
23. Connect and adjust the accelerator cable as described in paragraph 4.
24. Connect and adjust the high idle cable as described in paragraph 10.
25. Install the high pressure fuel pump sprocket and fit the timing belt as described in chapter 2B.
26.Install the intake manifold as described in paragraph 17.
27. Fill the fuel system as described in paragraph 6. Start the engine and check for signs of fuel leaks before installing the engine cover.
Models with 2.0L engine
Note. Installation will require a new high pressure fuel line installed between the fuel pump and the fuel rail.
Removing
28. Disconnect the ground wire from the battery (see «Disconnecting the battery»).
29. Remove the high pressure fuel pump sprocket as described in paragraph 9 of chapter 2B.
30. Disconnect the fuel supply and return fuel hose quick couplings at the top of the fuel pump while using a screwdriver to release the locking clip. Seal open connections appropriately to prevent dirt from entering.
31. Disconnect the fuel supply and return fuel hose quick couplings on the fuel filter in the same way and plug open connections. Release the fuel hoses (and on later models, a booster pump) from the corresponding clamps.
32. Remove the fuel filter from the appropriate support bracket and move it slightly away from the pump.
33. Remove the bolts and remove the filter support bracket from the engine.
34. Turn out bolts of fastening of a plastic directing plait of electroconducting to a forward part of the engine. To access the back of the fuel pump, you will need to lift the wiring harness as far as possible. If necessary, disconnect the appropriate electrical connectors to allow you to move the wiring harness assembly with the guide to further facilitate access.
35. Disconnect the pressure control valve electrical connector at the rear of the fuel pump and at the piston shutoff switch on the top of the pump.
36. Thoroughly clean the high pressure fuel line fittings at the fuel pump and fuel rail. Using an open end wrench, remove the union nuts securing the high pressure fuel lines to the fuel pump and fuel rail. When unscrewing the union nuts, hold the fittings on the pump and fuel rail with a second wrench. Remove the high pressure fuel line and plug open connections to prevent dirt from entering (pic. 13.36). Be aware that installation will require a new high pressure fuel line.
Pic. 13.36. High pressure fuel pump (models with 2.0 l engine)
1. High pressure pipeline
2. High pressure fuel regulator electrical connector
3. Bolts for fastening the rear bracket to the pump
4. Bolts for securing the rear bracket to the support bracket
5. Rear bracket
6. Fuel return hose
7. Pump front nuts/bolts
8. Fuel supply hose
9. Third piston shutoff solenoid valve electrical connector
10. Fuel line fitting
37. Turn away a nut and turn out a bolt of fastening of a back support of the fuel pump to a basic arm.
38. Turn away a nut and two bolts of fastening of a forward part of the fuel pump to a basic arm. Remove the pump along with the supply and return fuel hoses and remove it from the engine.
Warning. The high pressure fuel pump is manufactured to very tight tolerances and should never be dismantled. Do not unscrew the male fuel line fitting on the back of the pump or attempt to remove the pressure control valve, piston shutoff switch, or seal on the pump shaft. Pump elements are not supplied separately, and if a pump malfunction is suspected, it must be replaced.
Installation
39. Install the pump on the support bracket, screw on the nut and screw in the two pump mounting bolts from the front. Install the nut and bolt securing the fuel pump rear support to the support bracket, and then tighten all bolts/nuts to the specified torque.
40. Remove the plugs from the fuel line fittings on the pump and fuel rail. Connect the new high pressure fuel line to the fittings and at this stage hand tighten the union nuts.
41. Using a torque wrench and a special adapter, tighten the fuel line union nuts to the prescribed torque. When tightening the union nuts, hold the fittings on the pump and fuel rail with an open end wrench (pic. 13.41).
Pic. 13.41. When connecting a new high pressure fuel line to the pump and fuel rail, while tightening the union nuts to the prescribed torque, hold the corresponding fittings (models with 2.0 l engine)
42. Connect the pressure control valve electrical connector on the back of the fuel pump.
43. Replace and secure the plastic harness guide to the front of the engine and connect all other wiring disconnected for easy access.
44. Install filter support bracket to engine and tighten bolts securely. Position the fuel filter in the proper position on the support bracket.
45. Remove the plugs and connect the quick couplings of the supply and return hoses on the fuel filter and in the connections on the top of the fuel pump. Secure the hoses with appropriate clamps.
46. Install the high pressure fuel pump sprocket and fit the timing belt as described in chapter 2B.
47. Following the precautions described in paragraph 2, fill the fuel system as described in paragraph 6. Then start the engine and allow it to idle. Check the high pressure fuel line connections for leaks with the engine idling. If everything is in order, increase the engine speed to 4000 rpm and check for leaks again. Carry out a short road test of the vehicle and check for leaks again upon return. If leaks are found, purchase and install a new high pressure fuel line. Do not attempt to repair even the smallest leak by over-tightening the fuel line fittings
48. Finally, install the engine cover.