:	Jul 4, 2008

: 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 crankcase vent oil separator.

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

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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 fuel injection pump belt tensioner securing 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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:   Left-hand shown, right-hand similar. Remove the injector sound proofing.   Remove the 4 clips.

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Right hand (RH) high-pressure fuel supply line already removed when removing the crankcase vent oil separator.

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Release the left hand (LH) high-pressure fuel supply line.   Remove the bolt.

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: Make sure that the high-pressure fuel supply line remains in contact with the fuel injection supply manifold and the fuel injection pump until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system. Remove and discard the LH high-pressure fuel supply lines.   Install blanking caps to the exposed ports.

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Remove the timing belt rear cover access panel.   Remove the 2 bolts.

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Remove the fuel injection pump.   Remove and discard the 2 Torx bolts.   Remove and discard the 2 bolts.   Release the electrical connector.

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:   Do not disassemble further if the component is removed for access only. Using the special tool, remove the fuel injection pump pulley retaining nut.

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Using the special tool, remove the fuel injection pump pulley.

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Using the special tool, install the fuel injection pump pulley.   Clean the component mating faces.   Tighten the nut to 50 Nm (37 lb.ft).

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Install the fuel injection pump.   Clean the component mating faces.   Loosely install the new bolts.   Stage 1: Tighten the Torx bolts to 23 Nm (17 lb.ft).   Stage 2: Tighten the M8 bolts to 23 Nm (17 lb.ft).   Connect the electrical connector.

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Install the timing belt rear cover access panel.   Tighten the bolts to 10 Nm (7 lb.ft).

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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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Install the new left hand (LH) high-pressure fuel supply line.   Remove the blanking caps from the ports.   Clean the components mating faces.   Loosely install the new high-pressure fuel supply lines.   Stage 1: Tighten the high-pressure fuel supply line union at the fuel injection supply manifold to 15 Nm (11 lb.ft).   Stage 2: Tighten the high-pressure fuel supply line union at the fuel injection pump to 15 Nm (11 lb.ft).   Stage 3: Tighten the high-pressure fuel supply line union at the fuel injection supply manifold to 30 Nm (22 lb.ft).   Stage 4: Tighten the high-pressure fuel supply line union at the fuel injection pump to 30 Nm (22 lb.ft).

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Attach the LH high-pressure fuel supply line.   Align the clip.   Tighten the bolt to 10 Nm (7 lb.ft).

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

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Install the crankcase vent oil separator.

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Connect the battery ground cable.

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Bleed the fuel system.