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 fuel injection system electronic control unit (ECU) and ECU box.
3. Remove the intake manifold system and the upper portion of the 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 generator) on the side of the cylinder block.
7. Remove the bolts securing the wiring harness to the engine and move the fastener away from the fuel pump. You may have to disconnect some electrical connectors to move the wiring harness far enough. Label all connectors that you disconnect.
8. Remove the timing belt cover that covers the fuel pump pulley.
9. Unscrew the fuel supply and return hoses from the pump. Close the open ends of the hoses with appropriate 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. 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.
13. 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.
14. 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.
15. Unscrew the three front nuts (arrow) securing the pump.
16. Unscrew and remove the rear nut and bolt (indicated by an arrow), marking the location of the washers, and support the fuel pump on the beam.
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.
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 the timing belt cover.
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 accessory drive belt.
13. Install the upper intake manifold.
14. Install the ECU box and ECU unit.
15. Connect the negative battery terminal.
16. Remove air from the fuel system.