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 air intake pipes to improve access to the fuel pump.
3. Remove the auxiliary drive belt.
4. Remove the top casing of a gear belt.
5. Remove the hoses from the vacuum regulator at the end of the high pressure fuel pump.
6. Remove the accelerator cable from the high pressure fuel pump.
7. Mark the position and remove the fast idle cable from the high pressure fuel pump lever.
8. Disconnect the fuel supply line and plug it with a suitable plug (indicated by arrows).
9. Replace the removed fuel hose with a bolt (indicated by an arrow) to prevent the ingress of dirt.
10. Disconnect the fuel return line and plug it with an appropriate plug.
11. Disconnect all wires from the fuel pump (indicated by an arrow).
12. Remove the pipe nuts connecting the injector pipes to the high pressure fuel pump. Remove the pipes and protect them from dirt.
Attention! The ideal way to prevent dirt from getting into exposed fuel lines and connections is to cut off fingers from surgical rubber gloves, place them over the lines, and secure with rubber bands.
13. 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.
14. 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.
15. 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.
16. Remove the three front pump mounting nuts. Loosen and remove the rear nut and bolt, noting the location of the washers, and support the fuel pump on a bar.
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. Install and adjust the accelerator cable.
10. Connect the hoses to the vacuum regulator.
11. Establish the top casing of a gear belt.
12. Install the auxiliary drive belt.
13. Install the air intake pipes.
14. Connect the negative terminal of the battery.
15. Remove air from the fuel system.
16. Start the engine and check the high pressure fuel pump settings.