heres how to change a diesel pump for L400

[deligate]

posted on the aussie site www.delicaclub.com
Preliminary

Remove in no particular order
Intercooler
Rocker cover
Front stone trays
Air conditioner belt
Battery and battery box

Remove injector lines, fit caps to injectors immediately on removing injector lines

Important stuff
The pump is held to the timing cover plate by 2 nuts…. DO NOT LOOSEN these nuts
The pump is removed complete with mounting plate

Rotate engine till number 1 cylinder is firing at top dead centre, check this by inspecting camshaft and timing mark on front pulley

There is 1 bolt (14mm head) retaining the rear of the pump, below where the injector lines attach remove this and also fuel delivery line and fuel return line.
Remove accelerator cable and auto kickdown cable and vacuum line to a/c idleup device
Disconnect all electrical connections to pump and temperature sensors etc., disconnect boost hose to top of pump, and overflow rail return hose at rear of pump.
Disconnect 2 water hoses one immediately above pump, 1 vertical along side motor behind pump.
Plug or cap all disconnected lines as much as possible
The timing cover plate is held by 1 bolt from the back and 4 bolts from the front, the one from the back and 3 from the front are reasonably easy to and remove, the 4th at the front is behind the air con idler tensioner bracket, it is possible to undo (but not remove this bolt), the alternative is to undo the air con pump and then remove the pump mounting bracket, which I was avoiding to do. The pump can now be removed

More important stuff
Immediately on removing the pump, check the gear timing and the pump timing mark
There is 2 marks for the gear timing on the plate, and 1 of the gear teeth is marked and should align with one of the housing marks (probably the top mark), make sure this is the case, and which mark, as you will need when refitting
There is also a mark on the side of the pump flange near the mounting stud, which should align close to the mark on the mounting plate.

The whole unit with plate and gear can be removed to your local diesel shop for inspection or repair

On refitting the gear timing needs to be realigned, in good practise the pump should be retimed to specification, but requires special tools to do. The pump timing should be checked and reset immediately the pump is refitted to the motor, before refitting any hoses or injector lines, to set the timing the pump is rotated on the mounting plate, to the specified setting, you may need to get someone with correct tools to do this for you.
If you are going to ignore getting the pump timing checked, make sure the pump alignment marks are either returned to there original positions, or exactly aligned, depending on what was done to the pump.
BUT MUCH BETTER TO GET TIMING CHECKED and correctly set

If you are fitting a secondhand pump for some reason, get it check out and tested by your local diesel shop before fitting

quoted : westconn1 on the aussie site : www.delicaclub.com
hope this helps
mick and the delig8ter

[MardyDelica]

ah good mick,
realyy appreciate this stup;
cheers;