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

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

WARNING:

Be prepared to collect escaping fuel.
Wait for a minimum of 1 minute after the engine has stopped before carrying out any repair to the fuel injection system.

CAUTION:

Before disconnecting or removing components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.
Make sure that the area around the component is clean and free of foreign material.
Before disconnecting any components, make sure the area is clean and free from foreign material. "When" disconnected all openings must be sealed.

NOTE: This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

Disconnect the battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT
Remove the engine cover.
Refer to: ENGINE COVER - INGENIUM I4 2.0L DIESEL
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Remove the noise, vibration and harshness (NVH) material
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Detach the fuel lines.
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Disconnect the fuel rail fuel supply line.
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Install the blanking caps.
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Detach the oil level indicator bracket.
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Disconnect the fuel supply and return lines.
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Install the blanking caps.
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Remove the clip.
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Remove and discard the gasket and O-ring seal.
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Remove the fuel pump fuel supply line.
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Install the blanking cap.
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Disconnect the fuel pump fuel return line.
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Install the blanking caps.
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Disconnect the electrical connectors.
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Disconnect the electrical connector.
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Detach the exhaust gas recirculation (EGR) valve pipe.
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Remove and discard the gasket.
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Detach the EGR valve and position to one side.
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Detach the wiring harness.
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Detach the fuel rail fuel supply line from the fuel rail.
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Install the blanking cap.
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Remove the fuel line retaining bracket bolt.
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Detach the fuel rail fuel supply line from the fuel pump.
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Install the blanking cap.
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Remove and discard the fuel rail high pressure supply pipe.
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- Remove the 2 bolts.
- Remove the fuel pump sprocket access cover.
- Remove and discard the fuel pump sprocket access cover seal.
NOTE: Only rotate the crankshaft clockwise.

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Make sure that the alignment mark is at the 8 o'clock position, to aid correct installation of the special tool.
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Remove the components from the special tool to aid installation of the special tool.

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

Special Tool(s): JLR-303-1627

Torque : 10 Nm
CAUTION: Make sure that the special tool is correctly located.

NOTE: Only rotate the crankshaft clockwise.

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Rotate the engine and align the special tool to the fuel pump gear.

Special Tool(s): JLR-303-1627
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Fully install the special tool bolts.

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

Special Tool(s): JLR-303-1627
CAUTION: Do not remove the retaining bolts at this stage.

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Loosen the bolts as indicated in the illustration.
CAUTION: Do not remove the retaining bolt at this stage.

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Loosen the bolt as indicated in the illustration.
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Rotate the special tool to break the taper on the fuel pump shaft.

Special Tool(s): JLR-303-1627
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Detach the fuel pump until it stops on the retaining bolts.
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Remove and discard the retaining bolts.
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Remove and discard the retaining bolt.
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- Remove the fuel pump.
- Remove and discard the fuel pump seal.