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. Install the timing mechanism until the mounting holes are aligned, then turn the crankshaft a quarter turn counterclockwise.
10. Unscrew the plug from the injection timing adjustment hole located on the side of the fuel pump. If you do not have a special Peugeot adjustment rod, you can use a short rod with a diameter of 1.5 mm, one end of which is tapered.
11. Insert the Peugeot rod into the injection timing hole on the side of the fuel pump. Apply light pressure to the rod and slowly rotate the crankshaft in the direction of its working rotation until the Peugeot rod fits into the groove in the internal mechanism of the pump.
12. Remove all tools and position the crankshaft so that the mounting holes are aligned, then rotate the crankshaft a quarter 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 its working direction until the Peugeot rod fits into the groove in the internal mechanism of the pump. In this position, the valve timing mechanism is in the installation position and the locking rods should fit into the engine pulleys.
14. If adjustment is necessary, remove the setting rod from the pump, rotate the crankshaft to the setting position and lock 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 rotate the fuel pump towards the engine until the Peugeot rod fits into the groove in the internal mechanism of the pump.
15. Tighten the pump mounting nuts and bolts to the required torque.
16. Remove the Peugeot installation rod and close the hole with a plug.
17. Remove the crankshaft locking rod.
Installation
18. Install all previously removed components and parts.