Renault Koleos Service Repair Manual: High pressure pump: Removal - Refitting

M9R

Diesel injection

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair.

 

IMPORTANT Use the diagnostic tool before any operation is carried out on the injection circuit to check:
  • that the rail is not under pressure,
  • that the fuel temperature is not too high.

Working on the circuit with the engine running is strictly forbidden.

 

IMPORTANT During this operation, be sure to:
  • refrain from smoking or bringing red hot objects close to the working area,
  • be careful of fuel splashes when disconnecting the union.

 

WARNING Dismantling the interior of the high pressure pump and the injectors is prohibited.

 

WARNING To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Remove:
    • the engine cover
    • the battery
    • the battery tray
    • the injector rail protector

II - OPERATION FOR REMOVAL OF PART CONCERNED

  • Remove the high pressure pipe between the pump and the rail .

Diesel injection

  • Remove:
    • the quick-release union (1) from the high pressure pump supply pipe,
    • the quick-release union (2) from the high pressure pump return pipe.
  • Insert the blanking plugs.
  • Disconnect the high pressure pump pressure regulator connector.

Diesel injection

  • Remove:
    • the high pressure pump bolts (3) ,
    • the high pressure pump.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the high pressure pump O-ring,
    • the high pressure pump bolts,
    • the high pressure pipe between the high pressure pump and the injector rail,
    • the intercooler air inlet pipe seal.
  • Lubricate the new O-ring using engine oil.

If replacing the high pressure pump

Diesel injection

  • Secure the high pressure pump pinion in a vice's protective jaws.

Diesel injection

  • Fit the (Mot. 1906) (4) on the high pressure pump pinion.

Diesel injection

  • Fit:
    • the washers of the (Mot. 1906) on the high pressure pump,
    • the nuts (5) of the (Mot. 1906) on the high pressure pump.
  • Tighten the nuts (5) on the high pressure pump.

Diesel injection

  • Remove:
    • the high pressure pump pinion nut (6) ,
    • the nuts of the (Mot. 1906) from the high pressure pump,
    • the washers of the (Mot. 1906) from the high pressure pump,
    • the (Mot. 1906).

Diesel injection

  • Fit a separator (7) under the high pressure pump pinion (8) .

Diesel injection

  • Fit an arm (9) on the separator.
  • Remove:
    • the high pressure pump pinion,
    • the separator and the arm.
  • Refit:
    • the pinion to the new high pressure pump,
    • the high pressure pump nut,
  • Put the high pressure pump in a vice with jaws.
  • Fit:
    • the (Mot. 1906),
    • the washers of the (Mot. 1906) on the high pressure pump,
    • the nuts of the (Mot. 1906) on the high pressure pump.
  • Tighten the nuts on the high pressure pump.
  • Torque tighten the high pressure pump pinion nut (90 N.m).
  • Remove:
    • the nuts of the (Mot. 1906) from the high pressure pump,
    • the washers of the (Mot. 1906) from the high pressure pump,
    • the (Mot. 1906).

II - REFITTING OPERATION FOR PART CONCERNED

WARNING Do not remove the blanking plugs from each component until the last moment.

Also, do not remove the components from their packaging until they are to be fitted to the vehicle.

 

Note: Do not apply pressure to the high pressure pump pinion teeth.

Check that the high pressure pump is in contact with the cylinder head before positioning the bolts.

  • Refit the high pressure pump.

Diesel injection

  • Refit the high pressure pump bolts.
  • Torque tighten the high pressure pump bolts (initial torque) (5 N.m).
  • Torque tighten the high pressure pump bolts (25 N.m).
  • Remove the blanking plugs.
  • Refit the high pressure pipe between the pump and the injector rail.
  • Connect the fuel pressure regulator connector.
  • Connect:
    • the high pressure pump return pipe quick-release union,
    • the high pressure pump supply pipe quick-release union.

III - FINAL OPERATION

  • Fit the wiring.
  • Refit:
    • the seal of the intercooler air inlet pipe temporarily
    • the battery tray
    • the battery
  • Prime the fuel circuit using the manual priming pump.
  • Check for leaks.
  • Disconnect the intercooler air inlet pipe.
  • Move the intercooler air inlet pipe to one side.
  • Refit the injector rail protector.

Diesel injection

  • Remove the intercooler air inlet pipe seal using a .

Diesel injection

Note: Check that the intercooler air inlet pipe seal is fitted in the right direction.
  • Refit:
    • the new seal (10) of the intercooler air inlet pipe,
    • the protector plate on the injector rail protector.
  • Turn the intercooler air inlet pipe to refit the clip in its housing.
  • Clip the intercooler air inlet pipe onto the turbocharger.
  • Refit the intercooler air inlet pipe bolt on the fuel pipe support.
  • Torque tighten the intercooler air inlet pipe bolt (8 N.m).
  • Refit the engine cover.
    Crankshaft position sensor: Removal - Refitting

    Fuel pressure regulator: Removal - Refitting

    See More:

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