Before starting work, allow the engine to cool for 5 to 10 minutes to ensure the fuel pressure and temperature are at a minimum. The high-pressure fuel pump is removed after first removing the timing belt, and all high-pressure pipes removed must be renewed as a matter of course. Cleanliness is critical when working on the fuel system of any modern diesel engine, as even the smallest speck of grit or dirt can cause extensive damage to the pump and injectors; always clean thoroughly the pump and injector unions before dismantling, and immediately plug and seal all pipes and components, placing removed components in clean plastic bags. Begin by disconnecting the battery negative terminal, unscrewing the fuel tank filler cap to relieve any residual fuel pressure, and removing the inlet and outlet air ducts and hoses for access to the high-pressure fuel pump. For Type 2 engines, undo the nut and two bolts to remove the sensor bracket from the rear of the cylinder head, unclip the wiring loom cable ties from the upper plastic engine shield/cover, and then undo the two retaining bolts, releasing the two securing clips to lift off the upper plastic engine shield/cover. Next, undo the two retaining bolts and pull back the dipstick bracket from the front of the cylinder head, disconnect the wiring connector from the pressure sensor on the bottom of the fuel rail, release the securing clip to remove the wiring loom from the top of the lower plastic engine shield/cover, and where fitted, release the drain tube from the lower plastic engine shield/cover. Undo the bolt and two nuts to remove the lower plastic engine shield/cover, then undo the two bolts to remove the bracket from the front of the high-pressure fuel pump, and disconnect the three wiring connectors from the fuel pump. Place a clean rag over the alternator before removing the fuel pipes/hoses from the pump, wrapping them loosely in cloth/rag as a precaution against remaining pressure. The high-pressure pipe will need to be renewed, and the pump and pipes/hoses should be sealed immediately to prevent fuel contamination of the alternator. Remove the timing belt, noting that it would be sensible to renew it anyway, then unbolt and remove the fuel pump, placing it in a vice to remove the sprocket using a strap wrench and a ring spanner, with a puller required for the sprocket removal. Refitting is a reversal of removal, taking care not to place the new high-pressure pipe under any stress; if fitting a new pump, it is highly recommended to prime it with diesel on the bench before fitting. New high-pressure pipes come with a lubricant for the threads, and if none is supplied, the pipes are self-lubricating and should not have lubricant applied. Tighten all nuts and bolts to the specified torque and angle, prime and bleed the fuel system, and before restarting the engine, it may be necessary to use a diagnostic tool to clear any faults stored in the engine electronic control unit (ECU).
Posted by NissanPartsDeal Specialist 
