High-pressure pump

K9K

Essential special tools
Mot.1566	High-pressure pump pipe removal tool
Mot. 1367-02	Engine support
Mot. 1367	Engine support bar for cylinder head replacement
Mot.1606	High-pressure pump pulley holding tool
Mot.1525	High-pressure pump pulley puller
Mot.1525-02	High-pressure pump pulley puller jaws

Essential equipment

diagnostic tool

"low torque" torque wrench

high-pressure pipe spanner (DM19 spanner)

crowfoot pipe attachment for tightening the injector-to-rail high-pressure pipes ("Crowfoot 18-17" spanner)

crowfoot pipe attachment for tightening the pump-to-rail high-pressure pipe ("Crowfoot 19-17"

Tightening torques
high-pressure pump mounting bolts	2.1 +/- 0.2 daN.m
rail mounting nuts	2.8 +/- 0.3 daN.m
nut on rail side	3.8 daN.m
nut on pump side	3.8 daN.m
cover nut on rail	2.1 daN.m
high-pressure injection pump mounting bolts	2.1 +/- 0.2 daN.m
high-pressure injection pump pulley nut	1.5 +/- 0.1 daN.m + 60 +/- 10
rail mounting nuts	2.8 +/- 0.3 daN.m
fitting on rail side	3.8 daN.m
fitting on pump side	3.8 daN.m

There are two removal and refitting methods for the high-pressure pump.

IMPORTANT

Before any work on the injection system, use the diagnostic tool to check:

• that the injection rail is no longer under pressure,
• that the fuel temperature is not high.

• Always observe the safety and cleanliness instructions given in this document during every operation.
• Never loosen a high-pressure pipe connection while the engine is running.

WARNING

• Use the special plug kit for the high-pressure injection circuit.
• Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.

CAUTION: Never turn the engine in the reverse direction to its operating direction.

REMOVAL: METHOD 1

METHOD FOR HIGH-PRESSURE PUMPS WHOSE PULLEY IS MARKED NUMBER 070 575

WARNING

• It is strictly forbidden to remove any high-pressure pump pulley marked number 070575.
• Replace the "pump - pulley" assembly.

• Remove:

• the auxiliary drive belt (Chapter Upper and front engine, Auxiliary drive belt, page 11A-1),
• the timing belt (Chapter Upper and Front Engine, Timing Belt, page 11A-5).

• Remove the engine covers.
• Disconnect:

• the battery,
• the air intake duct (1).

• Remove the oil dipstick guide tube (2) and plug the opening on the engine block.
• Carefully disconnect:

• the glow plugs (3),
• the injectors (3),
• the electrical connectors on the high-pressure pump (4),
• the supply and return pipes (5).

• Carefully disconnect:

• the return pipe (6) connecting the injectors to the pump,
• the rail pressure sensor (7),
• the accelerator pedal sensor (8),
• the oil level sensor (9),
• the cylinder identification sensor (10) on the timing cover.

• Plug all openings in the injection circuit.
• Release the wiring harness from its clips, then move it aside.
• Remove the cover (11) located on the fuel rail.

• Loosen the rail mounting nuts (12) by a few threads.
• Remove the high-pressure pipe (13) connecting the pump to the rail. To do this:

• loosen the pump-side nut, then the rail-side nut,
• slide the long pipe nut back while keeping the olive in contact with the cone.

• Plug all openings in the injection circuit.

• Remove:

• the three high-pressure pump mounting bolts (14),
• the high-pressure pump.

REFITTING: METHOD 1

WARNING

Remove the protective plugs only at the last moment, for each component.

• Fit the high-pressure pump.
• Tighten the high-pressure pump mounting bolts to torque (2.1 +/- 0.2 daN.m).

CAUTION Always replace all high-pressure pipes that have been removed.

• Lightly lubricate the nut threads with the oil contained in the sachet supplied in the new parts kit, before fitting the new high-pressure pipe.

WARNING

• Some pipes are supplied with a sachet of oil and some are supplied without one.
• Pipes supplied without a sachet are self-lubricated. The tightening torque is unchanged: 3.8 daN.m.

• To refit the high-pressure pipe:

• remove the protective plugs,
• insert the high-pressure pipe olive into the cone at the high-pressure pump outlet,
• insert the high-pressure pipe olive into the cone at the rail inlet.

• Hand-tighten the high-pressure pipe nuts, starting with the nut on the rail side.
• Pre-tighten slightly.
• Tighten the rail mounting nuts to torque (2.8 +/- 0.3 daN.m).

CAUTION Do not turn the pipes with the wrench when tightening to torque.

• Tighten in sequence and to torque:

• the nut on the rail side (3.8 daN.m),
• the nut on the pump side (3.8 daN.m),

using tool (Mot.1566) and if necessary:

• a "low torque" torque wrench,
• a high-pressure pipe spanner (DM19 spanner),
• a flare-nut crowfoot for tightening the injector-to-rail high-pressure pipes ("Crowfoot 18-17" spanner),
• a flare-nut crowfoot for tightening the pump-to-rail high-pressure pipe ("Crowfoot 19-17" spanner).

• Tighten the union nut on the rail to torque (2.1 daN.m) using the "low torque" torque wrench.

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

WARNING

Check for diesel leaks:

• check the seal after the repair (Diesel Injection chapter, High-pressure pipe: Sealing check, page 13B-48),
• run the engine at idle until the radiator fan starts,
• rev the engine several times with no load,
• carry out a road test,
• switch off the ignition,
• check that no diesel is leaking.

REMOVAL: METHOD 2

METHOD FOR HIGH-PRESSURE PUMPS WHOSE PULLEY BEARS A NUMBER OTHER THAN 070575

• Position the vehicle on a two-post lift.
• Remove the engine covers.
• Disconnect the battery.

• Disconnect the air intake duct (15).

• Remove the oil dipstick guide tube (16) and plug the opening in the engine block.
• Carefully disconnect:

• the glow plugs (17),
• the injectors (17),
• the electrical connectors on the high-pressure pump (18),
• the supply and return pipes (19).

• Carefully disconnect:

• the return pipe (20) connecting the injectors to the pump,
• the rail pressure sensor (21),
• the accelerometer (22),
• the oil level sensor (23),
• the cylinder identification sensor (24) on the timing case.

• Release the wiring harness from its clips, then move it aside.
• Remove the cover (11) located on the fuel rail.

• Unscrew the rail mounting nuts (25) by a few threads.
• Remove the high-pressure pipe (26) between pump and rail (Diesel Injection chapter, High-pressure pipe: Replacement, page 13B-80).
• Loosen the nut on the pump side, then the nut on the rail side.
• Slide the nut along the pipe while keeping the olive in contact with the cone.
• Plug all openings in the injection circuit.

• Fit tool (Mot. 1367-02)(1) and tool (Mot. 1367).

• Remove the right-hand engine mount bracket together with its cover.

• Remove the upper timing cover by releasing the two tabs (27).

• Remove the mounting bolts (28) of the torque rod from the gearbox and from the engine cradle.
• Raise the engine a few centimetres to access the engine mount bracket mountings on the cylinder head and the high-pressure pump pulley.

CAUTION Do not disengage the right-hand driveshaft when raising the engine.

• Remove:

• the cylinder identification sensor (29),
• the plastic bolt (30).

• Release the three tabs (31).
• Remove the lower timing cover.

• Remove the engine mount bracket (32) from the cylinder head.

• Position the engine at top dead centre. The hole in the camshaft pulley must be aligned with the hole (33) in the cylinder head.

• Fit tool (Mot.1606)(3).

  If necessary, turn the engine slightly to align the locking tool with the teeth of the pump pulley.

• Remove the high-pressure pump pulley nut (34) while holding the pulley with an open-ended spanner.

• Fit tool (Mot.1525)(4) with tool (Mot.1525-02).

WARNING

Check that the tool thrust rod is aligned and bearing on the high-pressure pump shaft.

• Remove the three high-pressure pump mounting bolts (35).
• Screw in the thrust rod of tool (Mot.1525).
• Separate the pulley-pump assembly.
• Remove:

• the high-pressure pump,
• the high-pressure pump extractor tool.

REFITTING: METHOD 2

WARNING

Remove the protective plugs only at the last moment, for each component.

• Make sure the pulley locating pin is still in place.
• Fit the high-pressure injection pump.
• Tighten the high-pressure injection pump mounting bolts to torque (2.1 +/- 0.2 daN.m).
• Fit the nut for the high-pressure injection pump pulley.
• Tighten the high-pressure injection pump pulley nut to torque and angle (1.5 +/- 0.1 daN.m + 60 +/- 10°), holding the pulley with an open-ended spanner.
• Remove tool (Mot.1606).

CAUTION Always replace all high-pressure pipes that have been removed.

• Lightly lubricate the union threads with the oil contained in the sachet supplied in the new parts kit, before fitting the new high-pressure pipe.

WARNING

• Some pipes are supplied with a sachet of oil and some are supplied without one.
• Pipes supplied without a sachet are self-lubricated. The tightening torque is unchanged: 3.8 daN.m.

• To refit the high-pressure pipe:

• remove the protective plugs,
• position the high-pressure pipe olive in the cone at the pump outlet,
• position the high-pressure pipe olive in the cone at the rail inlet.

• Hand-tighten the high-pressure pipe unions, starting with the union on the rail side.
• Tighten the rail mounting nuts to torque (2.8 +/- 0.3 daN.m).
• Tighten in sequence and to torque:

• the fitting on the rail side (3.8 daN.m),
• the fitting on the pump side (3.8 daN.m).

• Check the high-pressure circuit for leaks after repair (Diesel Injection chapter, High-pressure pipe: Leak test, page 13B-48).
• Refit in the reverse order of removal.

  Prime the diesel supply circuit with the priming pump (bleeding is automatic).

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

WARNING

Check for diesel leaks:

• check the seal after the repair (Diesel Injection chapter, High-pressure pipe: Sealing check, page 13B-48),
• run the engine at idle until the radiator fan starts,
• rev the engine several times with no load,
• carry out a road test,
• switch off the ignition,
• check that no diesel is leaking.

F9Q

Essential special tools
Tool 1668	High-pressure pump gear locking tool
Mot.1525	High-pressure pump pulley puller
Tool 1525-03	Adapter jaws for Tool 1525 (for 33-tooth pulley)

Essential equipment

diagnostic tool

pipe union tool for tightening the high-pressure pump-to-rail pipe ("Crowfoot 19-17" spanner)

high-pressure pipe spanner (DM19 spanner)

"low torque" torque wrench

Tightening torques
high-pressure pump mounting bolts on the pump brackets	3 daN.m
high-pressure pump pulley nut	7 daN.m
high-pressure pump bracket mounting bolts on the cylinder head	2 daN.m + 80
rear high-pressure pump bracket mounting bolt on the cylinder block	4.4 daN.m
injection rail mounting nuts	2.2 daN.m
high-pressure pump-to-rail pipe nuts	2.5 daN.m
cover nut on rail	2.1 daN.m

IMPORTANT

Before any work on the injection system, use the diagnostic tool to check:

• that the injection rail is no longer under pressure,
• that the fuel temperature is not high.

Always observe the safety and cleanliness instructions given in this document during every operation.

Never loosen a high-pressure pipe connection while the engine is running.

WARNING

• Use the special plug kit for the high-pressure injection circuit.
• Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.

REMOVAL

• Position the vehicle on a two-post lift.
• Disconnect the battery.
• Remove:

• the auxiliary drive belt (Chapter Upper and front engine, Auxiliary drive belt, page 11A-1),
• the timing belt (Chapter Upper and Front Engine, Timing Belt, page 11A-5).

• Disconnect and move aside the oil vapour return pipe (1).

• Disconnect:

• the diesel heater on the diesel filter,
• the glow plugs,
• the pressure regulator (2),
• the pressure sensor (3).

• Disconnect the diesel supply and return pipes.
• Fit protective caps to the openings.
• Remove the clip securing the diesel pipes.

• Remove the high-pressure pump-to-rail pipe.
• Fit protective caps to the openings.

• Remove the two mounting bolts (4) of the high-pressure pump on the rear high-pressure pump bracket.

• Remove:

• the three mounting bolts (5) of the front high-pressure pump bracket,
• the high-pressure pump with the high-pressure pump bracket.

• Fit the tool (Tool 1668)(1).
• Remove the nut (6) from the high-pressure pump pulley.

• Fit the pulley puller (Tool 1525)(2), fitted with the jaws (Tool 1525-03) for the 33-tooth pulleys.
• Pull off the pulley by tightening the puller pressure screw (7).
• Remove the tools (Tool 1525), (Tool 1525-03), (Tool 1668).

• Remove:

• the three mounting bolts (8) of the high-pressure pump,
• the high-pressure pump.

INSTALLATION

WARNING

Remove the protective plugs only at the last moment, for each component.

• Refit the high-pressure pump on the pump bracket.
• Tighten to the following torques:

• the high-pressure pump mounting bolts on the pump brackets (3 daN.m),
• the high-pressure pump pulley nut (7 daN.m), holding the pulley still with the tool (Tool 1668).

• Push back the ring (9) as shown in the illustration.
• Loosen the two mounting bolts (10) of the rear high-pressure pump bracket on the cylinder block.
• Refit the complete high-pressure pump and pump bracket assembly.
• Tighten the high-pressure pump bracket mounting bolts on the cylinder head to torque (2 daN.m + 80 ).

WARNING

Do not stress the high-pressure pump-to-rail pipe or the rear pump bracket.

I - REFITTING THE REAR HIGH-PRESSURE INJECTION PUMP BRACKET

• Start the mounting bolts by hand so that the bracket contacts the high-pressure pump and the cylinder block.
• Tighten the rear high-pressure pump bracket mounting bolts on the cylinder block to torque (4.4 daN.m).

II - REFITTING THE HIGH-PRESSURE PUMP-TO-RAIL PIPE

• Loosen the injection rail mounting bolts (the rail must be "floating").

WARNING

• Before fitting a high-pressure pipe, lightly lubricate the nut threads with the oil in the sachet supplied in the new parts kit.
• Take care not to introduce oil into the high-pressure pipe.
• Do not lubricate high-pressure pipes supplied without a sachet; these pipes are self-lubricated.

CAUTION: Remove the caps only at the last moment for each component.

• Seat the high-pressure pipe flared end in the high-pressure outlet cone of the high-pressure pump.
• Seat the high-pressure pipe flared end in the inlet cone of the common rail.
• Start the high-pressure pipe nuts by hand, beginning with the rail-side nut.
• Pre-tighten the high-pressure pipe nuts lightly.
• Tighten the injection rail mounting nuts to torque (2.2 daN.m).

WARNING

• Do not put the spanner on the high-pressure pipes when tightening to torque.
• Always hold the injector intermediate fitting with a spanner while tightening.

• Tighten the high-pressure pump-to-rail pipe nuts (2.5 daN.m) in sequence and to torque, on both the pump side and the rail side, using the pipe union tool ("Crowfoot 19-17" spanner) or the high-pressure pipe spanner (DM19 spanner),

Note: Fully tighten one pipe before moving to the next pipe.

• Refit in the reverse order of removal.
• Refit:

• the timing belt (Section Top and front of engine, Timing belt, page 11A-5),
• the drive belt (Chapter Upper and front engine, Drive belt, page 11A-1).

• Prime the diesel circuit using the priming bulb.
• Tighten the union nut on the rail to torque (2.1 daN.m) using the "low torque" torque wrench.

WARNING

Connect the battery; carry out the necessary re-learns (see Electrical Equipment chapter).

WARNING

Check for diesel leaks:

• Check for leaks after repair (Diesel Injection chapter, High-pressure pipe: Leak test, page 13B-48).
• Run the engine at idle until the cooling fan starts.
• Rev the engine several times without load.
• Carry out a road test.
• Switch off the ignition.
• Check that there is no diesel leakage.