Special tool (s)
Crankshaft Oil Seal Remover/Installer 303-679 | |
Fuel pump sprocket locking tool 303-1151 | |
303-1149 Crankshaft Damper Pulley Remover | |
Fuel pump puller 303-1333 |
Removing
Warnings:
- Some fuel will inevitably spill during this operation. Ensure that all necessary precautions have been taken to prevent fire and explosion.
- Do not carry or use a cell phone while working on or in the vicinity of any fuel related items. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.
- Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. There is a danger of ignition of flammable vapours. Failure to follow these instructions may result in injury.
- If fuel gets in your eyes, rinse them with cold water or special eyewash solution and seek immediate medical attention.
- Wash your hands thoroughly after handling fuel as prolonged skin contact with fuel may cause irritation. Seek medical attention if irritation occurs.
- Do not carry out any repairs to the fuel system while the engine is running. The fuel pressure in the system can reach 2000 bar. Failure to follow this instruction may result in injury.
CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, when working with these nodes, absolute cleanliness is required. Be sure to install new plugs in all open holes and piping. Failure to follow this instruction may lead to the penetration of dirt into the fuel injection system.
1. Disconnect the wire "masses" from the battery.
For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).
2. Remove the accessory drive element bracket.
For more information, see chapter: Belt/Auxiliary Chain Tensioner Bracket (303-05 Accessory drive - ID4 2.4L diesel engine, Removal and installation).
3. Remove the vacuum pump of system of brakes.
For more information, see chapter: Brake vacuum pump (206-07 Vacuum brake booster, Removal and installation).
4.
WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.
Raise and support the vehicle.
For more information, see the chapter: Lifting the vehicle (100-02 Jacking and lifting the car on a lift, Description and principle of operation).
5. Drain the liquid from the cooling system.
For more information, see the chapter: Draining/refilling coolant and bleeding the cooling system (303-03 Engine Cooling - ID4 2.4L Diesel Engine, General Procedures).
6. Remove the water pump.
- Turn out 4 bolts.
- Remove the gasket and send it for recycling.
7. Disconnect the wiring harness.
8. Using a vacuum cleaner, remove foreign material from the high pressure fuel supply lines, fuel manifolds and high pressure fuel pump.
For more information, refer to the chapter: Cleaning the fuel injection system components (303-04A Fuel Supply and Controls - ID4 2.4L Diesel Engine, General Procedures).
9.
CAUTION: Plug all openings. Use new caps.
Release the pressure fuel line of the fuel pump
- 1. Turn out two bolts.
- 2. Remove the union of a pressure head fuel line of the fuel pump
10.
CAUTION: Plug all openings. Use new caps.
Disconnect the fuel injector from the high pressure fuel pump fuel line.
11.
CAUTION: Plug all openings. Use new caps.
Disconnect the fuel return line.
12. Disconnect the fuel metering valve and fuel temperature sensor.
13.
CAUTION: Plug all openings. Use new caps.
Remove and discard high pressure fuel pump feed line.
14. Using the special tool, remove the high pressure fuel pump drive gear cover.
15. Install special tools.
16. Remove the high pressure fuel pump drive gear.
- 1. Remove the nut.
- 2. Turn out two bolts.
17. Turn out 2 bolts from the fuel pump of a high pressure.
18. Using the special tool, remove the high pressure fuel pump.
19. Remove the high pressure fuel pump. Remove the O-ring and send it for recycling.
Installation
1. Install the high pressure fuel pump.
- Clean the contact surfaces of the parts.
- Install the sealing ring.
- Install the high pressure fuel pump bolts.
2. Attach the high pressure fuel pump. Tighten the bolts (tightening torque 23 Nm).
3. Install the high pressure fuel pump drive gear.
- 1. Tighten the nut (tightening torque 64 Nm).
- 2. Tighten the bolts to 33 Nm.
4. Remove the special tool.
5. Using the special tool, install the high pressure fuel pump drive gear cover.
6.
NOTE: Remove and discard plugs.
Install the new high pressure fuel supply line without tightening the bolts. Install the high pressure line clamps without tightening.
7. Install the pressure fuel line of the high pressure fuel pump. Tighten (tightening torque 35 Nm).
8. Attach the pressure fuel line of the high pressure pump.
- 1. Tighten (tightening torque 10 Nm).
- 2. Tighten (tightening torque 35 Nm).
9. Connect fuel metering valve and fuel temperature sensor.
10.
NOTE: Remove and discard plugs.
Connect the fuel return line.
11. Attach the wiring harness to the intake manifold.
12. Install the water pump.
- Install a new gasket.
- Tighten (tightening torque 23 Nm).
13. Fill in cooling liquid in the cooling system and remove air from the system.
For more information, see the chapter: Draining/refilling coolant and bleeding the cooling system (303-03 Engine Cooling - ID4 2.4L Diesel Engine, General Procedures).
14. Establish the vacuum pump of system of brakes.
For more information, see chapter: Brake vacuum pump (206-07 Vacuum brake booster, Removal and installation).
15. Install the accessory drive component bracket.
For more information, refer to chapter: Belt/Actuator Drive Bracket (303-05 Accessory drive - ID4 2.4L diesel engine, Removal and installation).
16. Connect the wire "masses" to the battery.
For more information, see the chapter: Connecting the Battery (414-01 Battery, Battery Mount and Wires, General Procedures).
17. Using the recommended Land Rover diagnostic system, perform the fuel pump learning procedure.
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