D 1.

5 TCI-U > High Pressure Fuel Pump > Removal

REMOVAL

● Common Rail Fuel Injection System is subject to extremely high pressure(Approximately 1,600
bar)
● Never perform any work on injection system with engine running or within 30 seconds after the
engine stops.
● Always pay attention to safety precaution.
● Ensure the absolute cleanliness
● It is not recommended to remove the injectiors without any notice.

1. Turn ignition switch OFF position.

2. Disconnect the negative battery(-) terminal and wait for about 30 seconds.
3. Disconnect the wiring connector of fuel pressure regulator.
4. Remove the high pressure pipe (A) connecting high pressure pump and common rail.

5. Disconnect the return hose(B) and the hose(C) connecting to the fuel filter.
6. Unscrew the three high pressure mounting bolts(D).
7. Remove the drive belt.(Refer to "EM" group.)
8. Turn the crankshaft pulley and align its groove with timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)

9. Remove the high pressure pump sprocket nut(G) after removing the timing chain cover plug(F).

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D 1.5 TCI-U > High Pressure Fuel Pump > Removal

10. Install the high pressure pump sprocket stopper(H) (SST: 09331-2A000) rotating it clockwise.

11. Fix the high pressure pump remover(I) and sprocket stopper(J) with two fixing bolts(K).
12. Install the high pressure pump remover(I) with three mounting bolts(E).
13. Rotate the bolt(L) of the high pressure pump remover(I) clockwise till the high pressure pump is
pushed out.

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