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. Install the timing mechanism until the mounting holes are aligned, then turn the crankshaft a quarter of a turn counterclockwise.
10. Unscrew the plug from the injection timing hole located on the side of the fuel pump. In the absence of a special Peugeot setting rod, a short rod with a diameter of 1.5 mm, one end of which is tapered, can be used.
11. Insert the Peugeot rod into the injection timing hole on the side of the fuel pump. With light pressure on the rod, slowly turn the crankshaft in the direction of its working rotation until the Peugeot rod is seated in the groove in the internal mechanism of the pump.
12. Remove all tools and install the crankshaft in alignment with the mounting holes, then rotate the crankshaft a quarter of a turn.
13. Insert the Peugeot rod into the injection timing hole on the side of the fuel pump. With light pressure on the rod, slowly turn the crankshaft in the direction of its working rotation until the Peugeot rod is seated in the groove in the internal mechanism of the pump. In this position, the timing mechanism is in the installation position and the locking rods should fit into the engine pulleys.
14. If adjustment is necessary, remove the adjusting rod from the pump, rotate the crankshaft to the installation position and block the pulleys with the locking rods. Loosen the front and rear pump mounting bolts and move the pump away from the engine. Insert the Peugeot setting rod into the injection timing hole on the side of the pump, press the Peugeot rod and slowly turn the fuel pump towards the engine until the Peugeot rod fits into the groove of the internal mechanism of the pump.
15. Screw nuts and bolts of fastening of the pump the demanded moment.
16. Remove the Peugeot installation rod and close the hole with a plug.
17. Remove the crankshaft lock rod.
Installation
18. Install all previously removed components and parts.