Peugeot 308: Removing - refitting : High pressure fuel pump

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

ESSENTIAL : Observe the safety and cleanliness recommendations specific to (THP) petrol direct injection engines .

1. Replacement of parts in all cases

Description	Quantity
High pressure fuel supply pipe	1
Seal (High-pressure pump)	1

2. Tooling

Workshop equipment : Diagnostic tool.

Tool	Reference	Description
	[0197-N][EN-52588]	Crankshaft setting pin
	[0189-Q] (*)	plugs kit
(*) Use standard workshop equipment if the special tool is not available

3. Depressurisation of the high pressure fuel circuit

ESSENTIAL : Carry out the depressurisation of the high pressure fuel circuit ; Using the diagnostic tool.

N.B. : A method can be found in the "Actuator tests engine off" menu ; Start the "Fuel supply circuit discharge" test.

4. Depressurisation of the low pressure fuel circuit

N.B. : A method can be found in the "Actuator tests engine off" menu ; Start the "Fuel supply circuit discharge" test.

5. Preliminary operations

Put the vehicle on a lift.

CAUTION : Perform the operations that are required prior to a disconnection of the ancillaries battery .

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Disconnect the ancillaries battery or batteries (depending on equipment).

Remove the engine cover .

6. Removing

CAUTION : Peg the engine flywheel ; Using the tool [0197-N / EN-52588].

Uncouple the fuel vapours recirculation pipe (1) (at "a", "b") (depending on equipment).

Slacken the clips (2).

Replace the union (3) of the air/air heat exchanger .

Remove :

• The 2 bolts (4)
• The turbocharger outlet air union (5)

Remove the heat protection (6) (depending on equipment).

N.B. : When disconnecting the fuel supply pipe (8), use a cloth to protect yourself from any fuel splashes.

Uncouple the fuel supply pipe (8).

CAUTION : Block the apertures of the high pressure fuel pump ; Using the plugs [0189-Q].

Disconnect the connector (at "c").

Uncouple the pipe (7).

Slacken the 2 bolts (10).

Move aside the electrical harness sheathing (9).

CAUTION : Clean the unions (13) and (15) of the high pressure fuel supply pipe (14) prior to slackening (if necessary).

Slacken the unions (13), (15).

Disconnect the connector (at "d").

Remove :

• The fuel high pressure supply pipe (14)
• The 2 bolts (12)
• The high pressure fuel pump (11)

CAUTION : Block the apertures of the high pressure fuel pump ; Using the plugs [0189-Q].

7. Refitting

CAUTION : Observe the tightening torques .

Remove the high pressure fuel pump (11) piston (17).

Check the condition of the roller push rod (16) (no signs of knocks or scratches).

Lightly lubricate the piston (17) before refitting.

Refit the piston (17) on the high pressure fuel pump (11).

Check the position of the lug "e" in the groove (at "f").

N.B. : Lubricate the seal lips when refitting.

Refit :

• The high pressure fuel pump (11) (With a new seal )
• The 2 bolts (12) (tighten by hand)
• The fuel high pressure supply pipe (14) (new)

Tighten the unions (13), (15) of the high pressure fuel pipe (14), to the end of the thread and by hand.

N.B. : The black union of the fuel high pressure supply pipe (14) must be positioned on the fuel high pressure common injection rail side.

Tighten the bolts (12) alternately to position the high pressure fuel pump (11) flush on its support.

Tighten the bolts (12) to the specified torque.

CAUTION : Tighten the components of the high pressure fuel circuit in the correct sequence .

Tightening stages :

• Pre-tighten the high pressure fuel pipe (14) unions (13), (15)
• Wait 30 seconds
• Tighten the high pressure fuel pipe (14) unions (13), (15)

Remove the tool [0197-N / EN-52588].

Reconnect the connector (at "d").

Refit the electrical harness sheathing (9).

Tighten the 2 bolts (10).

Couple up :

• The pipe (7)
• The fuel supply pipe (8)

Reconnect the connector (at "c").

CAUTION : Check the position of the heat shield (6) (depending on equipment) ; Risk of damage to the plastic components around the turbocharger .

Refit :

• The heat protection (6) (depending on equipment)
• The turbocharger outlet air union (5)
• The 2 bolts (4)
• The air/air heat exchanger union (3)

Tighten the clips (2).

Couple the fuel vapours recirculation pipe (1) (at "a", "b") (depending on equipment).

8. Additional operations

Refit :

• The engine cover
• The vehicle to its wheels

CAUTION : Perform the operations that are required after reconnecting the ancillaries battery .

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Reconnect the ancillaries battery or batteries (depending on equipment).

CAUTION : Carry out a seal check on the high pressure fuel circuit.