Fuel Pump - Vehicles Without: High Pressure Exhaust Gas RECIRCULATION Valve Cooler (G2300840): Installation

WARNING: This page is about a different variant/trim than selected.

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Remove the component from the special tool.

Special Tool(s): JLR-303-1627
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- Install a new fuel pump seal.
  Renew Part: Fuel pump O-ring seal Quantity: 1 .
- Lubricate the new seal with clean engine oil.
  Refer to: ENGINE - INGENIUM I4 2.0L DIESEL
CAUTION: Extreme cleanliness must be exercised when handling this component.

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Install the fuel pump.
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Install a new fuel pump retaining bolt.

Renew Part: Fuel pump drive sprocket nut Quantity: 1 .

Torque : 25 Nm
CAUTION: Make sure that the area around the component is clean and free of foreign material.

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Install 2 new fuel pump retaining bolts.

Renew Part: Fuel pump drive sprocket nut Quantity: 2 .

Torque : 25 Nm
CAUTION: Only tighten the nut finger tight at this stage.

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Install a new fuel pump sprocket retaining nut.

Special Tool(s): JLR-303-1627

Renew Part: Fuel pump drive sprocket nut Quantity: 1 .
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Loosen the bolts as indicated in the illustration.

Special Tool(s): JLR-303-1627
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Tighten the fuel pump sprocket retaining nut.

Special Tool(s): JLR-303-1627

Torque : 80 Nm
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Remove the special tool bolts.

Special Tool(s): JLR-303-1627
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Remove the special tool.

Special Tool(s): JLR-303-1627
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Install and lubricate a new fuel pump sprocket access cover seal with clean engine oil.
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Install the fuel pump sprocket access cover.

Torque : 11 Nm
CAUTION: Make sure that the component is clean, free of foreign material and lubricant.

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Install a new fuel rail high pressure supply pipe.

Renew Part: Fuel rail supply pipe(s) Quantity: 1 .
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Remove and discard the blanking cap.
CAUTION: Only tighten the union finger-tight at this stage.

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Attach the fuel rail fuel supply line to the fuel pump.
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Remove and discard the blanking cap.
CAUTION: Only tighten the union finger-tight at this stage.

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Attach the fuel rail fuel supply line to the fuel rail.
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Install the fuel line retaining bracket bolt.

Torque : 11 Nm
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Tighten the high-pressure fuel line to the fuel pump union.

Torque : 15 Nm
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Tighten the high-pressure fuel line to the fuel pump union 60°. This is the equivalent of one flat on the fuel line union, as illustrated.

Torque : 62.°
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Tighten the high-pressure fuel line to the fuel rail union.

Torque

Stage 1: 10 Nm

Stage 2: 62°
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Attach the wiring harness.

Torque : 11 Nm
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Attach the EGR valve.

Torque : 9 Nm
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Install a new gasket.

Renew Part: EGR pipe to exhaust manifold gasket Quantity: 1 .
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Attach the EGR valve pipe.

Torque : 11 Nm
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Connect the electrical connector.
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Connect the electrical connectors.
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Remove and discard the blanking caps.
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Connect the fuel pump fuel return line.
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Remove and discard the blanking cap.
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Connect the fuel pump fuel return line.
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- Make sure that a new gasket and O-ring seal is installed.
  Renew Part: EGR outlet pipe to throttle body gasket Quantity: 1 .
  
  Renew Part: EGR pipe to intake manifold O-ring seal Quantity: 1 .
  
  Torque
  
  M6x20: 7 Nm
  
  M6x25: 11 Nm
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Install the clip.
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Remove and discard the blanking caps.
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Connect the fuel supply and return lines.
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Attach the oil level indicator bracket.

Torque : 11 Nm
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Remove and discard the blanking caps.
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Connect the fuel rail fuel supply line.
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Attach the fuel lines.
Connect the battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
CAUTION: Bleed the fuel system by cranking the engine to purge the air from the system.

Bleed the fuel system.

Refer to: HIGH-PRESSURE FUEL SYSTEM BLEEDING or LOW-PRESSURE FUEL SYSTEM BLEEDING
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Install the NVH material.
Install the engine cover.
Refer to: ENGINE COVER - INGENIUM I4 2.0L DIESEL