Supplementary pressure pump - r r

Operation 1060E40 · Diesel pressure pump

Removing

Proceed with the removal - 5530B10 battery - r+r.

Proceed with the removal - 5530B52 Battery DRIP TRAY/SUPPORT - R.R..

Proceed with the removal - 4450B12 front or rear wheels (two) - r+r.

Proceed with the removal - 1044B10 fuel filter assembly - r + r or replace.

Proceed with the removal - 7210E22 R.R. WINDSCREEN BASE TRIM.

Proceed with the removal - 7055B54 under-engine guard - r r.

Proceed with the removal - 7210E10 R.R. FRONT BUMPER.

Drain the air conditioning system - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling.

Proceed with the removal - 4130B10 power steering fluid resevoir r r.

Proceed with the removal - 1088B10 engine cooling tank - r + r.

Proceed with the removal - 1004B10 power unit with manual gearbox - r + r.

1. Working at the bench, undo the bolt (1a) and the nut (1b) and remove the engine oil dipstick tube (1c) complete with dipstick.

1. Disconnect the electrical connection for the cam angle sensor.

2. Disconnect the electrical connection from the solenoid on the vacuum tank.

Move the electrical wiring to the side.

1. Adjust the moving tensioner to loosen the engine components single drive belt tension.

2. Remove the engine components single drive belt.

1. Open the cover (1a), undo the nuts (1b) and disconnect the electrical connections (1c) for the alternator.

1. Undo the bolts (1a) and remove the alternator (1b).

2. Remove the spacer.

1. Undo the bolt (1a) and move the electrical wiring mounting bracket (1b) aside.

1. Undo the bolts (1a) and remove the intermediate drive shaft mounting (1b) complete with upper alternator bracket (1c).

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).

2. Undo the bolt (2a) and remove the single drive belt fixed tensioner (2b).

1. Undo the nuts (1a) and remove tool (1b) temporarily.

Ensure the power unit is positioned securely on the workbench.

2. Undo the nuts (2a) and remove the power unit timing side rigid engine mount (2b).

Fit the tool again and secure with nuts.

1. Undo the bolts (1a) and remove the timing gear covers (1b).

1. Adjust the drive pulley bolt and rotate the crankshaft until the timing marks line up (cylinder no. 1 at T.D.C.).

2. Check that the locating dowel on the timing belt drive pulley is facing downwards.

3. Loosen the nut (3a) for the timing belt moving tensioner and remove the timing drive belt (3b).

1. Screw two bolts in the appropriate seats to stop the rotation of the pressure pump pulley.

2. Undo the pressure pump pulley nut.

Remove the two bolts used to stop the rotation of the pressure pump pulley.

1. Remove the pressure pump pulley (1a) using the tool (1b).

1. Release the fuel pipes from the fastenings on the air chamber.

2. Undo the bolts (2a) and remove the fuel return manifold pipe (2b), complete with pipes (2c).

1. Disconnect the electrical connection from the fuel pressure regulator on the fuel pump.

2. Undo the connector for the pipe from the pressure pump to the fuel manifold (2a), manifold side, using tool (2b).

3. Undo the connector for the pipe from the pressure pump to the fuel manifold, pump side, using a suitable commercial wrench.

4. Remove the pipe from the pressure pump to the fuel manifold.

When refitting, fit a new pipe from the pressure pump to the fuel manifold.

1. Undo nuts (1a) and remove pressure pump (1b) from its mount.

1. Undo nuts (1a) and remove tool (1b) temporarily.

Ensure the power unit is securely positioned on the workbench.

2. Undo bolts (2a) and (2b) and remove pressure pump mount (2c).

Refitting

1. Place the pressure pump support (1a) back in its housing and secure it tightening the bolts (1b) and (1c) to the recommended torque.

Fit the tool again and secure with nuts.

1. Fit the clutch pump (1a) back in its housing and tighten the nuts (1b) to the specified torque.

1. Place the pipe from the pressure pump to the single fuel manifold back in its housing and fix it using the connectors without tightening them.

2. Tighten the connector for the pipe from the pressure pump to the fuel manifold, pump side, to torque using a suitable commercial wrench

3. Tighten the connector for the pipe from the pressure pump to the fuel manifold (3a), manifold side, to the recommended torque using a tool (3b).

Connect the electrical connection to the pressure regulator on the pressure pump.

Place the fuel return manifold pipe back in its housing and secure it using the bolts.

Secure the fuel delivery pipe to the fastenings on the air chamber.

Refit the pressure pump drive pulley in its seat and secure with the nut without tightening.

Screw two bolts in the appropriate seats to stop the rotation of the pressure pump pulley.

1. Tighten the nut (1a) securing the pressure pump drive pulley to the recommended torque, using tool (1b).

Remove the two bolts used to stop the rotation of the pressure pump pulley.

1. Undo the bolt for the crankcase front cover shown in the diagram.

Temporarily fit the timing drive belt on the drive pulley.

2. Fit the tool (2a) and secure it with gauged bolts (2b)

To allow the engagement of the locating dowel on the timing drive belt drive pulley in the opening in the tool, rotate the crankshaft using small movements.

1. Check that the timing references coincide.

2. Completely fit the timing belt.

1. Use a screwdriver for leverage in the opening (1a) so that the reference on the tensioner (1b) is aligned with the opening reference (1c) and, in this position, tighten the moving tensioner nut (1d) to the recommended torque.

Remove the tools.

Tighten the bolt for the crankcase front cover previously removed.

Rotate the crankshaft through two revolutions.

Check once again that the timing references and the tensioning references on the mobile timing tensioner coincide.

Place the protective timing covers back in their housings and secure them using the bolts.

Undo the nut and remove the tool temporarily.

Ensure the power unit is securely positioned on the workbench.

1. Refit the gearbox side power unit rigid support (1a) in its seating and secure with nut (1b).

2. Refit tool (2a) and secure with nuts (2b).

1. Place the engine components single drive belt fixed tensioner (1a) back in its housing and fix it tightening the bolts (1b) to the recommended torque.

2. Place the crankshaft pulley (2a) back in its housing and ecure it tightening the nut (2b) to the recommended torque.

1. Refit intermediate drive shaft (1a) complete with upper alternator mount bracket (1b) and secure it by tightening bolts (1c) to the specified torque.

Place the intermediate drive shaft mount back in its housing and secure it using the bolt.

1. Place the alternator (1a), complete with spacer (1b), back in its housing and secure it by tightening bolts (1c) to the recommended torque.

Connect the electrical connections to the alternator, secure them using the nuts and close the cover.

Adjust the moving tensioner and fit the engine components single drive belt.

Connect the electrical connection to the solenoid on the vacuum tank.

Connect the electrical connection for the cam angle sensor.

Place the complete engine oil dipstick tube back in its housing and secure it with the nut and bolt.

Proceed with the refitting - 1004B10 power unit with manual gearbox - r + r.

Proceed with the refitting - 1088B10 engine cooling tank - r + r.

Proceed with the refitting - 4130B10 power steering fluid resevoir r r.

Refill the air conditioning system - 5040A10 Air conditioning refrigerant CIRCUIT - Draining and Refilling.

Proceed with the refitting - 7210E10 R.R. FRONT BUMPER.

Proceed with the refitting - 7055B54 under-engine guard - r r.

Proceed with the refitting - 7210E22 R.R. WINDSCREEN BASE TRIM.

Proceed with the refitting - 1044B10 fuel filter assembly - r + r or replace.

Proceed with the refitting - 4450B12 front or rear wheels (two) - r+r.

Proceed with the refitting - 5530B52 Battery DRIP TRAY/SUPPORT - R.R..

Proceed with the refitting - 5530B10 battery - r+r.