B1HG1IK1 - 206 DW8 ENGINE

REMOVAL - REFITTING INJECTION PUMP (LUCAS)

1 - SPECIAL TOOLS

DW8 ENGINE

[1] Injection pump setting pin LUCAS (-).0188-H .

ALL MODELS

2 - PRECAUTIONS TO BE TAKEN

DW8 ENGINE

Electronic immobiliser .

1st case : Possible to lock and unlock the module .

NOTE : before the pump is removed, the module must be unlocked .

Unlocking procedure :

• open the driver's window
• close all the doors on the vehicle
• switch on the ignition (without opening the doors)
• wait for 10 seconds (approximately)
• switch off the ignition (without opening the doors)

WARNING : if a door is opened after switching off the ignition, wait 15 seconds and re-start the whole procedure .

Disconnect the engine ECU or the pump module .

WARNING : the time allowed for removing the component concerned is 10 minutes ; if this time is exceeded, re-start the whole procedure .

This procedure ensures that the module is properly unlocked .

This is the only procedure which allows a pump bench test (without replacing the module) .

Bench testing the pump : .

With the module unlocked, the pump can operate, when there is feed to the solenoid via the connector secured to the pump (4-way black) :

• (terminal 1) = +12 V
• (terminal 4) = earth

2nd case : Impossible to lock and unlock the module .

DW8 ENGINE

Repair : Refer to method described in brochure : PEUGEOT immobiliser .

IMPERATIVE : diagnosis : before any removal ; refer to method described in brochure : PEUGEOT immobiliser .

ALL MODELS

3 - REMOVAL

DW8 ENGINE

Disconnect the battery .

Remove :

• the style cover (1)
• the air distributor (2)
• the EGR valve hose (3)

Unclip and separate :

• the fuel pipes (4)
• the expansion pipe (5)
• the ECU (6)

Disconnect and move aside : The pipe (7) .

Unclip :

• the accelerator cable (8)
• the fast idle cable (9)

Remove the injection pipes (10) .

Disconnect the connectors (11)-(12) .

Remove :

• the ancillary drive belt
• the timing belt
• the injection pump pulley (using tool [1])

Remove :

• the 3 securing bolts (13)
• the pump rear fastening
• the injection pump
• the tool [1]

ALL MODELS

4 - REFITTING

DW8 ENGINE

Check the presence of the bolt (14) and the spacer (15) on the injection pump mounting .

Refit the injection pump .

Refit the 3 securing bolts at the front of the pump : Tightening torque 2.0 da.Nm .

Tighten the nut (16) to 2.25 da.Nm .

Fit : The injection pipes (Tightening torque : 2.5 da.Nm) .

Fit :

• the tool [1]
• the injection pump pulley (17)
• the 3 securing bolts (18)

Tightening torque : 2.3 da.Nm .

Fit :

• the timing belt
• the ancillary drive belt

Continue the fitting operations in the reverse order to removal .

Initialise the various ECUs .