:	Sep 4, 2006

: Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

: Do not carry out any repairs to the fuel system with the engine running. The fuel pressure within the system can be as high as 1650 bar (23,931 lb-sq-in). Failure to follow this instruction may result in personal injury.

: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

: Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

: Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

: Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

: Do not disassemble or clean inside the fuel pump, even with an ultrasonic cleaner. Always install a new fuel pump when required.

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Disconnect the battery ground cable.

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Remove the engine cover.

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Clamp the exhaust gas recirculation (EGR) coolant hoses to minimize coolant loss.

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Disconnect the coolant hoses.   Release the clips.

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Remove the EGR coolant cross-over pipe.   Remove the two retaining bolts.

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Remove the injector sound proofing.   Remove the 2 clips.

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Release the knock sensor (KS) harness from the valve cover.

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Release the glow plug harness from the valve cover.

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Disconnect the fuel injector electrical connectors.

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Release the engine wiring harness.   Release the four clips.

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Release the fuel charging wiring harness.   Release the 3 clips.   Remove the 2 nuts.

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Disconnect the breather line.   Release the clip.

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Remove the fuel injection pump belt cover.   Reposition the engine wiring harness to allow access to the fuel injection pump belt cover.   Release the 3 clips.

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:   The fuel injection pump belt is not timed to the engine. Remove and discard the fuel injection pump belt tensioner.   Remove and discard the bolt.

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:   The fuel injection pump rotates in a counter-clockwise direction when viewed from the rear of the engine. Remove and discard the fuel injection pump belt.

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: Make sure that the fuel injection pump belt tensioner tang is correctly located to the fuel injection pump belt rear cover. Failure to follow this instruction may result in damage to the engine. :   Do not remove the fuel injection pump belt tensioner locking pin at this stage. Install a new fuel injection pump belt tensioner.   Clean the components mating faces.   Locate the tang on the new fuel injection pump belt tensioner into the fuel injection pump rear cover.   Tighten the bolt to 25 Nm (18 lb.ft).

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: Do not install the new fuel injection pump belt to the pulleys with the fuel pump belt tensioner locking pin removed. Failure to follow this instruction may result in damage to the fuel pump belt. :   The fuel injection pump rotates in a counter-clockwise direction when viewed from the rear of the engine. Install the new fuel injection pump belt.   Make sure the components are clean and dry.

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Remove and discard the fuel injection pump belt tensioner locking pin.

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Install the fuel injection pump belt cover.   Secure with the 3 clips.   Reposition the engine wiring harness to allow access to the fuel injection pump belt cover.

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Attach the fuel charging wiring harness.   Secure with the 3 clips.   Tighten the nuts to 10 Nm (7 lb.ft).

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Secure the engine wiring harness.

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Connect the fuel injector electrical connectors.

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Secure the glow plug wiring harness.

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Secure the KS wiring harness.

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Install the injector sound proofing.   Secure with the 2 clips.

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Connect the breather line.   Secure with the clip.

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Install the EGR coolant cross-over pipe.   Install the two retaining bolts.   Tighten to 13 Nm (10 lb.ft).

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Connect both EGR coolant cross-over pipe hoses.   Remove the EGR coolant hose clamps.

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Connect the battery ground cable.

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Check and top-up the coolant.