Contents: Removal ⬇ Installation ⬇
Removal
1. Place the vehicle on a two-post lift.
2. Disconnect the battery, starting with the negative cable.
3. Disconnect the wiring connector from the air flow meter, wiring connector 1 from the boost pressure sensor (figure 4.74). Remove the air filter, engine cover and air duct 2.
Figure 4.74. Disconnect wiring connector 1 from the boost pressure sensor.
4. Remove the front license plate and radiator grille.
5. Unscrew the headlight mounting bolts (figure 4.75).
Figure 4.75. Unscrew the headlight mounting bolts.
6. Disconnect the wiring connectors from the headlights.
7. Remove the headlights by detaching the clips (figure 4.76).
Figure 4.76. Remove the headlights by detaching the clips.
8. Remove the bumper (figure 4.77a, b).
Figure 4.77a. Remove the bumper.
Figure 4.77b. Remove the bumper.
9. Remove the power steering fluid reservoir from the bracket.
10. Remove the hood locking mechanism and its release cable.
11. Remove the front cross member and engine guard.
12. Disconnect the exhaust gas recirculation pipe (figure 4.78).
Figure 4.78. Disconnect the exhaust gas recirculation pipe.
13. Disconnect the bracket between the air distributor and the power steering pump (figure 4.79).
Figure 4.79. Disconnect the bracket between the air distributor and the power steering pump.
14. Disconnect the wiring connector from the EGR solenoid valve.
15. Loosen the air distributor mounting bolts and disconnect the connecting pipe from the intake manifold (figure 4.80).
16. Install the TDC locking tool Mot. 1536.
17. Disconnect the high pressure regulator, fuel temperature sensor, pressure and return fuel lines from the fuel pump and plug the holes, disconnect the fuel vapor recovery tube.
18. Unhook the protective cover of the high pressure accumulator and remove it.
Figure 4.80. Loosen the air distributor mounting bolts and disconnect the connecting pipe from the intake manifold.
19. Disconnect the high pressure fuel lines and plug the holes.
20. Remove the support cylinder sensor, carefully remove the sealing ring without damaging it, and remove the plug in the pump cover (figure 4.81).
Figure 4.81. Remove the support cylinder sensor, carefully remove the sealing ring without damaging it, and remove the plug in the pump cover.
21. Fit tool Mot. 1548 with centering pin (figure 4.82).
Figure 4.82. Fit tool Mot. 1548 with centering pin.
22. Remove the centering pin after installing the fixture.
23. Remove the TDC locking tool Mot. 1536.
24. Unscrew the central nut securing the pump hub, locking the flywheel with a screwdriver.
25. Loosen the three bolts 3 securing the pump to the bracket by a few turns (figure 4.83).
Figure 4.83. Loosen the three bolts 3 securing the pump to the bracket by a few turns.
26. Release the pump by screwing in the guide pin of tool Mot. 1548 (figure 4.84).
Figure 4.84. Release the pump by screwing in the guide pin of tool Mot. 1548.
27. Unscrew the mounting bolts and remove the high-pressure fuel pump.
Installation
28. Installation is carried out in the reverse order of removal.
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