High Pressure Pump Removal and Installation
Precautions: Precautions for Fuel System Service · General safety (00)
Before performing the following procedure, observe Precautions for Fuel System Service:D16AA.
Removal
1)Release fuel pressure. 
2)Remove engine assembly.
3)Remove generator.
4)Remove timing belt.
5)Remove high pressure pipe between high pressure pump and common rail.
6)Disconnect fuel flow actuator connector from fuel flow actuator.
7)Disconnect fuel hose (1) from high pressure pump (2).
8)Fix high pressure pump pulley using bolts (2) of M6 size and 1.00 mm pitch.
9)Remove high pressure pump pulley nut (1).
10)Remove bolts of M6 size and 1.00 mm pitch.
11)Fit special tool to high pressure pump pulley using bolts (3) of M6 size and 1.00 mm pitch.
12)Remove high pressure pump pulley (1) by tightening bolt (2) of special tool.
13)Remove engine harness brackets from high pressure pump mounting.
14)Loosen high pressure pump mounting bolts (1), and remove high pressure pump mounting (2) with high pressure pump.
15)Remove high pressure pump from high pressure pump mounting.
Installation
1)Install high pressure pump (1) to high pressure pump mounting (2).
2)Install high pressure pump mounting (1) with high pressure pump.
a)Tighten adjusting bolt (2) of high pressure pump mounting comes contact with cylinder head.
b)Tighten new high pressure pump mounting No.2 bolts (3) to specified torque.
3)Install engine harness brackets to high pressure pump mounting.
4)Fix high pressure pump pulley (1) using bolts (2) of M6 size and 1.00 mm pitch.
5)Tighten high pressure pump pulley nut (3) to specified torque.
6)Remove bolts of M6 size and 1.00 mm pitch.
7)Connect fuel hose to high pressure pump. Clamp fuel hose using special tool.
8)Connect fuel flow actuator connector to fuel flow actuator.
9)Install high pressure pipe between high pressure pump and common rail.
10)Install timing belt.
11)Install generator.
12)Install engine assembly.
13)Check for fuel leakage.