Rear High Pressure Fuel Pump (G2268897): Removal

WARNING: This page is about a different variant/trim than selected.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTION:

Make sure that tools and equipment are clean and free of foreign material and lubricant.
Before disconnecting any components, make sure the area is clean and free from foreign material. When disconnected all openings must be sealed.

NOTE:

This procedure contains illustrations showing certain components removed to provide extra clarity.
This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.

Always follow the fuel system health and safety precautions when doing any repairs to the fuel system.
Refer to: PETROL AND PETROL-ETHANOL FUEL SYSTEMS HEALTH AND SAFETY PRECAUTIONS .
NOTE: Make sure the engine is warm.
- Start the engine and allow to run for 10 minutes.
- Stop the engine after 10 minutes.
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- Allow 10 minutes from turning the engine off before starting the oil extraction process.
- Remove the oil filler cap.
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Using the special tool, drain the oil out through the oil extraction pipe.

Special Tool(s): 303-1484 , 303-1484-01
Fully drain the engine oil then remove the special tool.
Remove the Special Tool(s): 303-1484 , 303-1484-01
Partially drain the cooling system.
Refer to: COOLING SYSTEM PARTIAL DRAINING AND VACUUM FILLING .
Release the fuel pressure.
Refer to: FUEL SYSTEM PRESSURE RELEASE .
Disconnect the startup battery ground cable.
Refer to: STARTUP BATTERY DISCONNECT AND CONNECT .
Remove the air filter outlet pipe T-connector.
Refer to: AIR FILTER OUTLET PIPE T-CONNECTOR .
CAUTION: Be prepared to collect escaping engine coolant.

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Disconnect the 2 coolant hoses from the left side of the charge air cooler.
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Release the 2 pipes.
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Remove the oil filler cap and Noise, Vibration and Harshness (NVH) material.
CAUTION: Be prepared to collect escaping engine coolant.

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Disconnect the 2 coolant hoses from the right side of the charge air cooler.
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Release the vacuum pipe from the NVH material and disconnect the union.
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Remove the NVH material.
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Release the wiring harness retaining clip.
Clean the fuel injectors, High Pressure (HP) fuel delivery line and surrounding areas.
Refer to: FUEL INJECTION COMPONENT CLEANING .
CAUTION: Be prepared to collect escaping fuel.

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- Remove the 4 bolts.
- Disconnect the 2 fuel unions.
- Remove the fuel line.
CAUTION: Be prepared to collect escaping fuel.

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- Remove the nut.
- Release the fuel union.
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Remove the nut from the engine mount bracket.
Raise and support the vehicle on a suitable 2 post lift.
Refer to: LIFTING .
Remove the engine undershield.
Refer to: ENGINE UNDERSHIELD - INGENIUM I4 2.0L DIESEL AJ21/INGENIUM I4 2.0L PETROL/INGENIUM I6 3.0L DIESEL/INGENIUM I6 3.0L PETROL .
Remove the front right halfshaft.
Refer to: FRONT HALFSHAFT .
Remove the generator.
Refer to: REMOVAL AND INSTALLATION .
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- Remove the 3 bolts.
- Remove the idler pulley.
CAUTION: Use a wooden block to protect the oil pan when supporting the engine.

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Using a transmission jack support the engine.

General Equipment: Transmission jack
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Remove the 2 bolts from the engine mount.
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Release the clip from the engine mount bracket.
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- Remove the 2 bolts.
- Remove the engine mount bracket.
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- Remove the 3 bolts.
- Remove the halfshaft support bracket.
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Remove and discard the O-ring seal.
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- Disconnect the 2 electrical connectors.
- Release the 3 clips.
- Position the wiring harness to one side.
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- Remove the 2 bolts.
- Remove the fuel line heatshield.
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Remove the bolt.
CAUTION: Be prepared to collect escaping fuel.

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Release the 2 fuel unions.
CAUTION: Be prepared to collect escaping fuel.

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- Remove the 2 bolts.
- Release the 2 fuel unions.
- Remove and discard the HP fuel delivery lines.
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Remove the NVH material.
CAUTION: Be prepared to collect escaping oil.

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- Loosen the bolts a turn each at a time.
- Remove the HP fuel pump.
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Remove the HP fuel pump tappet.