Removal
Place a suitable container, to collect any engine oil and fuel which may leak out.
Disconnect the fuel flow regulator from the high pressure pump
In order to facilitate the operations, remove the engine wiring as described in the relative procedure.
Figure 69
229303
Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump.
Ref. No. Description
(2) 1 M8x1.25
Figure 70
218891
Undo the fitting (1) and disconnect the fuel high pressure pipe from the fuel manifold pipe
Ref. No. Description
Figure 71
229304
Undo the fitting (2) and disconnect the high pressure fuel pipe from the high pressure pump.
Undo the bracket nut (1) and remove the high pressure fuel pipe.
Ref. No. Description
(1) 1 M8x1.25
(2) 1 M16x1
Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to:
- disconnect the pipelines when the engine is working;
Figure 72
227800
Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger.
Ref. No. Description
(1) 1 M22x1.5
Figure 73
227801
Loosen clamp (1), disconnect the quick- connector (2) to remove both the low pressure pipes from the high pressure pump and take them out from the clips.
Figure 74
227803
Undo the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder.
Undo the screws (1) and remove the water/oil heat exchanger (2) with the relative gasket and the engine cooling water pipe.
Ref. No. Description (1) 8 M8x1.25x30
(3) 1 M8x1.25
Unscrew and remove the screw (5), unscrew and remove screws (1) with their washers (3).
Remove the high pressure pump (2) from its support (4). Ref. No. Description
(1) 2 M8x1.25x90
Figure 75
229313
Unscrew and remove the screw (5), unscrew and remove screws (1) with their washers (3).
Remove the high pressure pump (2) from its support (4). Ref. No. Description
(1) 2 M8x1.25x90
(5) 1 M6x1x20
Refitting
If a new high pressure pump is fitted, it is delivered by Bosch in its stable position (BDC) with flange fitted.
If the high pressure pump is not replaced, it must be positioned in its stable position (BDC) by turning the control shaft as appropriate.
The relative position between control shaft and pump axis is determined by the flange fitted on the pump.
Figure 76
220106
Remove the inspection caps from the overhead and turn the crankshaft with a suitable wrench until you can see the camshaft timing hole, and fit specific tools 99360614 (1).
Ref. No. Description
(-) 2 M14x1.5x10
NOTE To reinstall the high pressure pump, the camshafts and crankshaft must be in phase.
NOTE Two revolutions of the crankshaft correspond to one revolution of the camshafts.
Figure 77
220130
Lubricate a new seal ring (3) and fit it to the high pressure pump.
Make sure the flange (4) is fitted to the high pressure pump. Make sure the high pressure pump is in stable equilibrium, with the one of the two recesses (1) on the flange (4) in line with the reference on the pump itself (2).
Fit the pump (2) in such a way that the teeth of the control shaft engage in the cross housings (1).
Figure 78
135043
Make sure you are in vertical mounting position.
Figure 79
229313
Fit the high pressure pump (2) vertically as shown in the previous figure onto the support (4) and rotate it in an anticlockwise direction until the mounting bolt holes are aligned.
Tighten screw (5) and screws (1) with their washers (3) to the torque indicated in the table.
Remove specific tools 99360614 and reinstall the camshaft timing inspection caps on the cylinder overhead.
Ref. No. Description Tightening
torques (1) 2 M8x1.25x90 25±2.5 (5) 1 M6x1x20 25±2.5 (-) 2 M14x1.5x10 25±2.5 Figure 80 227803
Fit the water/oil heat exchanger (2), with a new gasket and tighten the screws (1) to the torque indicated in the table. Tighten the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder to the torque indicated in the table.
Ref. No. Description Tightening
torques
(1) 8 M8x1.25x30 25 ± 2.5
Figure 81
227801
Connect both low pressure pipes supported by the clips to the high pressure pump and fit a new clamp (1) and engage quick-connector (2).
Figure 82
227800
Place the oil filter (1) on the water/oil heat exchanger and tighten to the torque indicated in the table.
Ref. No. Description Tightening
torques
(1) 1 M22x1.5 25 ± 2.5
Figure 83
α
229304
Fit the new high pressure fuel pipe and tighten the bracket nut (1) to the torque indicated in the table.
Connect the high pressure fuel pipe to the high pressure pump and tighten the fitting (2) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening.
Ref. No. Description Tightening
torques (1) 1 M8x1.25 25±2.5 (2) 1 M16x1 1stphase 25±2 2ndphase 90˚ Figure 84 α 218898
Connect the high pressure fuel pipe to the fuel manifold pipe and tighten the fitting (1) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening.
Ref. No. Description Tightening
torques
(1) 1
M15x1
1stphase 24±2
Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to:
- re-use the disassembled pipelines.
Figure 85
229303
Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table.
Ref. No. Description Tightening
torques
(2) 1 M8x1.25 25 ± 2.5
Connect the fuel flow regulator to the high pressure pum p. Fit the engine wiring as described in the relative proce dure.
ELECTRIC EXHAUST GAS FLAP