Page 169 of 2492
DIESEL EQUIPMENT
Pump
13
SPECIAL TOOLING REQUIRED
B.Vi. 868 Wrench for removing high
pressure pipe
Mot. 909-02 12 sided wrench for removing
injection pump mounting
Mot. 997 Socket for removing injector
holder
Mot. 1053 Pump pulley extractor
Mot. 1054
TDC pin
Mot. 1200 Pump pulley retaining tool
REMOVAL
Battery disconnected, remove:
- the suspended engine mounting housing (1),
- the injection pump pulley housing (2).
DI1302-199183R
Immobilise the engine using tool Mot. 1054. To do
this, turn the engine so that the camshaft sprocket
index is aligned with the timing cover reference
mark.
Disconnect the fuel supply pipe at the injection
pump end.
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DIESEL EQUIPMENT
Pump
13
Fit the pump pulley retaining tool Mot. 1200. Remove:
- the fuel return pipe,
- the high pressure pipe using tool B.Vi. 868,
- the accelerator cable,
- the connections,
- the fast idle control,
- the four rear mounting bolts,
99333-1R
Remove the pump sprocket mounting nut.
Release the sprocket from the cone using tool
Mot. 1053 (fit two plastic clips before removing
the sprocket).
99333R
99336-1R
- the three injection pump mounting bolts; to
make removing the lower bolt easier, use tool
Mot. 909-02.
Remove the pump (retain the key from the drive
cone).
13-24
Page 171 of 2492
DIESEL EQUIPMENT
Pump
13
92600R2
BBOSCH pump
RLUCAS DIESEL pump
Ckeyway to be used
13-25
Page 172 of 2492
DIESEL EQUIPMENT
Pump
13
REFITTING (Special notes)
To facilitate refitting the lower injection pump
mounting bolt, remove the injector holder for
cylinder n° 4 (when refitting, the copper seal and
the flame arresting washer must be systematically
renewed).
Refitting is the reverse of removal.
IMPORTANT : depending on equipment, the
pump drive sprocket has a different position.
There are two position markers and two
differently aligned keyways.
Fit the pump ensuring the key fits into the
sprocket (reference C).
Tighten the pump mounting nut to the
recommended torque (see previous pages).
Carry out pump timing (see method below).
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Page 173 of 2492
DIESEL EQUIPMENT
Pump - timing
13
CHECKING THE PUMP TIMING
In place of the plug (1) insert the dial gauge
mounting Mot. 856 and attach a dial gauge with
socket.
99336R
Zero the dial gauge to BDC on the injection pump
piston.
Immobilise the engine using tool Mot. 1054. To do
this, turn the engine so that the camshaft sprocket
index is aligned with the timing cover reference
mark.
DI1303-1
99183R
Check the pump piston lift shown on the dial
gauge ; it should be 0.82 ± 0.04 mm. If it is not,
rotate the pump to obtain the required piston lift.
IMPORTANT : after tightening the pump
mounting bolts, turn the engine over twice.
Immobilise the engine once more to check the
pump timing.
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Page 174 of 2492
DIESEL EQUIPMENT
Coded solenoid valve
13
REPLACEMENT
SPECIAL TOOLING REQUIRED
Mot. 1372 Kit for removing self shearing
bolts from computers
REMOVAL
This operation must be carried out with the
ignition turned off.
Remove the oil vapour decanter (1).
DI1410-1
Fit the drilling tube (2) from kit Mot. 1372 into the
computer.
Use:
- the 4 mm diameter drill from kit Mot. 1372 to
drill the two bolts (drilling depth
approximately 3 mm),
- the number 6 extractor from the kit Mot. 1372
to remove the bolts.
99780R
Remove the computer.
REFITTING
Use the self shearing bolts available from the Parts
Department.
Composition of kit Mot. 1372 :
- one 4 mm diameter drill (4)
- one number 6 extractor(3)
- one drilling tube (2)
NOTE :
- take care to remember to replace the plastic
cover on the solenoid valve nut,
- lightly oil the drill to facilitate drilling.
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Page 175 of 2492
DIESEL EQUIPMENT
Operating diagram
13
PRJ99256
13-29
Page 176 of 2492

DIESEL EQUIPMENT
Pre-post-heating unit
13
DIAGRAM KEY
104Ignition switch
163Starter
171Air conditioning clutch
206Air conditioning trifunction pressure switch
247Instrument panel
251Bi-function coolant temperature switch
257Pre-heating unit
398EGR solenoid valve
412Fast idle solenoid valve (AC version)
597Engine fuse box
642AC / pre-heating separation diode
645Passenger compartment fuse box
680Pre-heating unit n° 1
681Pre-heating unit n° 2
682Pre-heating unit n° 3
683Pre-heating unit n° 4
711Diesel fuel pump
741Altimetric capsule
743Altimetric relay
777Power feed for fuse boxConnector (A)
+ Bat+ before ignition feed
Connector (B)
1Feed to heater plugs 1 and 3
2Feed to heater plugs 2 and 4
Connector (C)
A1 / S2Load dependence solenoid valve
control
A2 / PCLoad lever microswitch information
A3 / CTNCTN type sensor coolant temperature
information
B1/+APC+ after ignition feed
B2 / DEMStarter information
B3 / TemPre-heating warning light control (via
earth)
C1 / S1Not used
C2 / -Bat Earth
C3 / ClimFast idle solenoid valve control during
post-heating phase
92206-2R
IDENTIFICATION OF CONNECTORS
13-30