BOSCH high pressure fuel pump installation (Peugeot 405)

Bosch high pressure fuel pump and injectors

Placing a dial indicator on the Bosch high pressure fuel pump during installation

1. Remove the cylinder head cover.

2. Install the engine crankshaft so that the #1 cylinder exhaust valve is at the start of the opening.



3. Remove the cover (arrow) inspection hole located at the back of the pump.


4. Tilt the pump out of the engine.

5. On XUD 7TE engines, be sure to disable the cold start control.

6. Install a dial gauge with bracket 0117 AK1 and extension 0117 AK2 in the mounting hole.

7. While cranking the engine, find the bottom dead center of the high pressure fuel pump separator piston.

8. Reset the dial indicator.

9. Rotate the engine crankshaft until the valves of cylinder #1 begin to open (this corresponds to the TDC of the piston of cylinder No. 4).

10. Lock the engine flywheel in this position.

11. Slowly turn the pump in the injection advance direction until the dial gauge behind bottom dead center shows the desired value.

12. Tighten the pump fasteners to the correct torque.

Checking the installation

These steps are performed after the pump has been installed.

1. Remove the element that fixes the flywheel.

2. Turn the crankshaft 1/4 turn in the opposite direction of its rotation.

Attention! Turn the crankshaft in accordance with the direction of rotation and fix it at the TDC of the No. 4 cylinder piston.

3. In this position, the dial indicator should indicate the correct value. If the value indicated by the sensor does not correspond to the required value, then the pump should be installed again.

4. Remove the pump mounting hardware and unscrew the bolts securing the pump pulley.

5. Install the inspection port cover, upper drive housing and glow plugs.

6. On XUD 7TE engines, connect the cold start control.

7. Follow the rest of the steps in reverse order with respect to disassembly.

8. Remove air from the fuel system.

9. Adjust idle speed.