Fuel Pump — Range: 2007->CURRENT (Discovery 3)

Special tool

Retaining device 310-161

Puller 310-160

Removal

CAUTION: Do not carry or use a cellular telephone while working on or near any fuel related component. There is a risk of ignition of flammable vapors. Failure to follow these instructions may result in personal injury.

WARNING: Do not perform any repairs to the fuel system while the engine is running. Fuel pressure in the system can reach 1650 bar. Failure to follow this instruction may result in personal injury.

CAUTION: Do not smoke or keep lighted cigarettes or open flames of any type away when working on or near fuel related items. There is a risk of ignition of flammable vapors. Failure to follow these instructions could result in personal injury.

CAUTION: When performing the following work, care must be taken when handling fuel. Always be prepared for possible fuel splashes and follow fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTION: Make sure that the area of the workshop where the vehicle is being serviced is as clean and dust-free as possible. Dirt and dust from clutch, brake, machining or welding work can contaminate the fuel system and cause problems later.

CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to do so may result in dirt entering the fuel injection system.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, it is especially important to maintain absolute cleanliness when working with these components. Be sure to insert plugs into all open holes or lines. Failure to do so may result in dirt entering the fuel injection system.

CAUTION: Do not disassemble or clean the inside of the fuel pump, even with ultrasound. Always install a new fuel pump if necessary.

1. Disconnect the battery ground cable. For more information, refer to Specification.

2. Remove the engine crankcase ventilation oil separator.

3. Release the fuel injection system wiring harness.

(The article is based on information from the website LRMAN.RU)

• Release the 3 clamps.
• Unscrew 2 nuts.

4. Remove the fuel pump belt cover.

• Move the engine wiring harness to gain access to the fuel pump belt cover.
• Release the 3 clamps.

5.

NOTE: The fuel pump belt is not synchronized with the engine.

Remove and discard the fuel pump belt tensioner. Loosen the high pressure fuel pump drive belt tensioner mounting bolt and discard it.



6.

NOTE: The fuel pump rotates counterclockwise when viewed from the rear of the engine.

Remove and discard the fuel pump belt.

7.

NOTE: Left side shown, right side is done in the same way.

Remove the fuel injector noise insulation. Remove the 4 clamps.

NOTE: The right high pressure fuel supply line is already removed when the crankcase ventilation oil separator was removed.

8. Release the left high pressure fuel supply line. Remove the bolt.

9.

CAUTION: Make sure that the high pressure fuel supply line remains in contact with the fuel pump and fuel supply manifold until both connections have been disconnected and cleaned. Failure to do so may result in dirt entering the fuel injection system.

Remove the left high pressure fuel supply lines and discard them. Insert plugs into the open holes.



10. Remove the timing belt rear roof inspection panel. Remove the 2 bolts.



11. Remove the high pressure fuel pump.

• Unscrew and discard the 2 Torg bolts.
• Remove and discard 2 bolts.
• Release the electrical connector.

12.

NOTE: Do not continue disassembly if the component is removed only for access.

Using a special tool, unscrew the high pressure fuel pump pulley nut.



13. Using the special tool, remove the high pressure fuel pump pulley.

Installation

1. Using the special tool, install the high pressure fuel pump pulley.

• Clean the mating surfaces of the elements.
• Tighten the nut to 50 Nm.

2. Install the high pressure fuel pump.

• Clean the mating surfaces of the elements.
• Screw in new bolts without tightening.
• Step 1: Tighten the Torx bolts to 23 Nm.
• Step 2: Tighten the M8 bolts to 23 Nm.
• Connect the electrical connector.

3. Install the timing belt rear roof inspection panel. Tighten the bolts to 10 Nm.

4. CAUTION: Make sure the fuel pump belt tensioner tailpiece is correctly positioned relative to the fuel pump belt rear cover. Failure to do so may result in engine damage.

NOTE: Do not remove the fuel pump belt tensioner retaining pin at this stage.

Install a new fuel pump belt tensioner.

• Clean the mating surfaces of the elements.
• Insert the end of the new fuel pump belt tensioner into the rear fuel pump belt cover.
• Tighten the bolt to 25 Nm.

5.

CAUTION: Do not install the new fuel pump belt onto the pulleys with the fuel pump belt tensioner retaining pin removed. Failure to follow this instruction may result in damage to the fuel pump belt.

NOTE: The fuel pump rotates counterclockwise when viewed from the rear of the engine.

Install a new fuel pump belt. Make sure the parts are clean and dry.

6. Remove and discard the fuel pump belt tensioner locking pin.





7. Install the fuel pump belt cover.

• Secure with 3 clamps.
• Move the engine wiring harness to gain access to the fuel pump belt cover.

8. Connect the fuel injection system wiring harness.

• Secure with 3 clamps.
• Tighten the nuts to 10 Nm.

9. Install the new left high pressure fuel supply line.

• Remove plugs from exposed connections.
• Clean the mating surfaces of the elements.
• Install new high pressure fuel supply lines, but do not tighten them permanently.
• Step 1: Tighten the high pressure fuel supply line nipple connection on the fuel rail to 15 Nm.
• Step 2: Tighten the high pressure fuel supply line nipple connection on the fuel pump to 15 Nm.
• Step 3: Tighten the high pressure fuel supply line nipple connection on the fuel rail to 30 Nm.
• Step 4: Tighten the high pressure fuel supply line nipple connection on the fuel pump to 30 Nm.

10. Secure the left high pressure fuel supply line.

• Check the position of the clamp.
• Tighten the bolt to 10 Nm.

11. Install the left fuel injector noise insulation. Secure the two clamps.

12. Install the engine crankcase ventilation oil separator.

13. Connect the battery ground cable. For more information, refer to Specification.

14. Bleed the fuel system. For more information, refer to Bleeding the Low-Pressure Fuel System (19.50.07)