Table of contents: Removal 🠇 Installation 🠇
Caution: Be careful not to allow dirt to enter the fuel pump or high pressure line when working on the fuel pump. Also, always use a new seal.
Removal
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 upper timing belt cover.
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 speed cable from the high pressure fuel pump lever.
8. Disconnect the fuel supply line and plug it with the appropriate plug (indicated by arrows).
9. Install a bolt in place of the removed fuel hose (indicated by the arrow) to prevent dirt from getting in.
10. Disconnect the fuel return line and plug it with a suitable plug.
11. Disconnect all wires from the fuel pump (indicated by the arrow).
12. Unscrew the pipe fastening nuts that connect the injector pipes to the high-pressure fuel pump. Remove the pipes and protect them from dirt.
Caution: The ideal way to prevent dirt from getting into exposed fuel lines and connections is to cut the fingers off of surgical rubber gloves, place them over the lines and secure with rubber bands.
13. Using the crankshaft pulley, turn the crankshaft in the direction of engine rotation until the two bolt holes in the high-pressure fuel pump pulley align with the corresponding holes in the engine. The engine will turn more easily if the glow plugs are removed.
14. Insert two M8 bolts through the holes in the fuel pump pulley. These bolts will hold the pulley in place while the high pressure fuel pump is removed, so you don't have to remove the timing belt.
15. Mark the position of the high pressure fuel pump relative to the installation mount using a scriber or felt-tip pen (the mark is indicated by an arrow). This will ensure that the fuel injection timing is maintained when reinstalled in the same location.
16. Remove the three front pump mounting nuts. Remove and discard the rear nut and bolt, noting the location of the washers, and support the fuel pump on a block.
17. Separate the fuel pump pulley from the pump shaft.
18. Remove the pump carefully.
Installation
1. Replace the woodruff key on the pump shaft.
You can find the original on the page peugeotbook
2. Place the pump in place and support it on a block as you did when removing it.
3. Install the pulley onto the fuel pump shaft.
4. Align the marks made on the pump and the unit hanger before removal. Install and lightly tighten the pump mounting nuts and bolt.
5. Set the fuel pump injection timing.
6. Install and re-tighten the lines connecting the fuel pump to the injectors.
7. Connect the fuel supply and return hoses.
8. Connect the high idle speed cable to the pump lever.
9. Install and adjust the accelerator cable.
10. Connect the hoses to the vacuum regulator.
11. Install the upper timing belt cover.
12. Install the auxiliary drive belt.
13. Install the air intake pipes.
14. Connect the negative battery terminal.
15. Remove air from the fuel system.
16. Start the engine and check the high pressure fuel pump settings.