Attention! Be careful not to get dirt into the fuel pump or high pressure pipe when working on the fuel pump. Also, always use a new seal.
Removing
1. Disconnect the negative battery terminal.
2. Remove the electronic control device of the fuel injection system (ECU) and the ECU box.
3. Remove the intake piping and upper intake manifold.
4. Remove the auxiliary drive belt.
5. Remove the alternator.
6. Unscrew the bolts and remove the intermediate bracket (power steering pump and alternator) side of the cylinder block.
7. Unscrew the bolts securing the wiring harness to the engine and move the fastener away from the fuel pump. You may need to unplug some electrical connectors to move the wire harness a sufficient distance. Label all disconnectable connectors.
8. Remove the timing belt cover covering the fuel pump pulley.
9. Unscrew the supply and return fuel hoses from the pump. Close the open ends of the hoses with suitable plugs.
10. Disconnect the electrical wires from the pump and the hose clamps.
11. Unscrew the nuts securing the injector pipes to the fuel pump.
12. At the crankshaft pulley, rotate the crankshaft in the direction of engine rotation until the two bolt holes in the injection pump pulley line up with the corresponding holes in the engine. The engine will crank more easily if the glow plugs are unscrewed.
13. Insert two M8 bolts through the holes in the fuel pump pulley. These bolts will hold the pulley while the high pressure fuel pump is removed so the timing belt does not have to be removed.
14. Mark the position of the high pressure fuel pump in relation to the installation suspension, using a scriber or felt-tip pen (the label is indicated by an arrow). This will ensure that the fuel injection timing is maintained when reinstalled.
15. Remove the three front nuts (arrow) pump mountings.
16. Loosen and remove rear nut and bolt (indicated by an arrow), marking the location of the washers, and support the fuel pump on a block.
17. Separate the fuel pump pulley from the pump shaft.
18. Carefully remove the pump.
Installation
1. Reinstall the key on the pump shaft.
2. Reinstall the pump and support it on a beam as in the removal process.
3. Install the pulley on the fuel pump shaft.
4. Align the marks made on the pump and mounting bracket before removal. Install and lightly tighten the nuts and pump mounting bolt.
5. Set the injection timing of the fuel pump.
6. Install and retighten the lines connecting the fuel pump to the injectors.
7. Connect the supply and return fuel hoses.
8. Connect the high idle cable to the pump lever.
9. Establish a casing of a gear belt of a drive.
10. Install the wiring harness retainer to the engine and reconnect the previously disconnected connectors.
11. Install the intermediate bracket to the cylinder block.
12. Install the alternator, power steering pump and auxiliary drive belt.
13. Install the intake manifold top.
14. Install the ECU box and the ECU.
15. Connect the negative terminal of the battery.
16. Remove air from the fuel system.