Link to video of injector/crank issue

HI MGT.
The engine will need to be raised a little to get to the drive sprocket nut, and use the tool.

Just to reiterate above you will need a 17mm large Allen key to remove the outer screw plug, or you can use a nut from the donor engine injector pipes has here below.
1

2

3

4

Once the cap/plug is undone and removed it will expose the drive sprocket nut,
5

6

Undo and remove the drive sprocket nut again 17mm/19mm can't remember now.
7

8

Once the nut is removed you can then screw in the outer part of the special tool.
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10

Next screw in the other part of the tool to the shaft where the nut was removed by hand only.
11

Nip this up the spanner.
12

This leaves the main bolt sticking out ready to turn in to push out the drive sprocket/HPFP.
13

Before you now try and push out the HPFP you must remove any fuel rails connected to it, and the three 13mm bolts holding it in place, removing the manifold helps with this, has you have more access, some also remove the starter motor, that is where you may have read to lock the engine, but the HPFP can be removed without removing the starter motor it just makes it a bit more awkward.
14

15

16

17

18

With all the nuts removed and fuel rails/feed pipes you can now turn the main bolt 24mm spanner or adjustable, this will push out the HPFP.
19

20

Has you tighten the bolt the HPFP will come loose.
21

Make sure you keep the metal gasket.
22

From this photo you can see the ball bearing of the special tool.
23

From this angle it shows you the chain.
24.

You will then need to re-fit the new HPFP, to do this you offer the HPFP up, and add the three nuts, once it starts to get hold you will have to back off the main bolt a bit at a time making sure the HPFP is fully inserted.

Arctic2 said:

HI MGT.
The engine will need to be raised a little to get to the drive sprocket nut, and use the tool.

Just to reiterate above you will need a 17mm large Allen key to remove the outer screw plug, or you can use a nut from the donor engine injector pipes has here below.

1

2

3

4

Once the cap/plug is undone and removed it will expose the drive sprocket nut,

5

6

Undo and remove the drive sprocket nut again 17mm/19mm can't remember now.

7

8

Once the nut is removed you can then screw in the outer part of the special tool.

9

10

Next screw in the other part of the tool to the shaft where the nut was removed by hand only.

11

Nip this up the spanner.

12

This leaves the main bolt sticking out ready to turn in to push out the drive sprocket/HPFP.

13

Before you now try and push out the HPFP you must remove any fuel rails connected to it, and the three 13mm bolts holding it in place, removing the manifold helps with this, has you have more access, some also remove the starter motor, that is where you may have read to lock the engine, but the HPFP can be removed without removing the starter motor it just makes it a bit more awkward.

14

15

16

17

18

With all the nuts removed and fuel rails/feed pipes you can now turn the main bolt 24mm spanner or adjustable, this will push out the HPFP.

19

20

Has you tighten the bolt the HPFP will come loose.

21

Make sure you keep the metal gasket.

22

From this photo you can see the ball bearing of the special tool.

23

From this angle it shows you the chain.

24.

You will then need to re-fit the new HPFP, to do this you offer the HPFP up, and add the three nuts, once it starts to get hold you will have to back off the main bolt a bit at a time making sure the HPFP is fully inserted.

Click to expand...

That is bloody amazing, thanks very much. Tool should arrive early next week and I will report back after job done. Without this forum I would never have got further than replacing a bulb.

MGT said:

I've ordered that tool. Thanks. If you don't mind another question, I've just watched a video on how to remove the HPFP, which made sense except for the bit about locking the engine with a bolt. My knowledge is obviously pretty limited - I learn as I do things - and I couldn't see from the video where that bolt goes in. I suppose I can experiment with the engine I have on the bench, but I would rather not mess that up.

Click to expand...

Locking the engine just needs a pry bar through the starter motor hole to lock the ring gear. This allows easy undo & re-tighten of the HPFP sprocket bolt. Also with starter motor out, access to the pump bolts is easier.

Also as you have a donor engine & HPFP, get two seal kits & do both pumps. X8R do a complete kit for £22.

pwood999 said:

Locking the engine just needs a pry bar through the starter motor hole to lock the ring gear. This allows easy undo & re-tighten of the HPFP sprocket bolt. Also with starter motor out, access to the pump bolts is easier.

Also as you have a donor engine & HPFP, get two seal kits & do both pumps. X8R do a complete kit for £22.

Click to expand...

That's great, thanks. It's a good idea. I'm wondering now if there's anything else down there that's prone to failure and easy to swap. I've already done the crank sensor and map sensor. Not sure whether it's worth doing the glow plugs if I don't have to - read they are given to snap.

Check the plastic y-shape coolant thingy on the front of the engine. They do leak, so changing it now saves taking the inlet stuff off later.

pwood999 said:

Check the plastic y-shape coolant thingy on the front of the engine. They do leak, so changing it now saves taking the inlet stuff off later.

Click to expand...

Thanks.