FUEL SUPPLY PUMP REMOVAL


  1. REMOVE ENGINE UNDER COVER

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E01

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap, then drain the coolant.

    3. Close the radiator drain cock plug.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf, for the engine drain plug }

  4. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CJ11E01

      Set the No. 1 cylinder to TDC/compression.

      Tech Tips

      Make sure that there is free play in the No. 1 cylinder rocker arms and that there is no free play in the No. 4 cylinder rocker arms.

  5. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH

  6. REMOVE NO. 2 INTAKE PIPE


    1. A01CHOY

      Remove the 3 bolts, loosen the 2 bands, and remove the No. 2 intake pipe.

  7. REMOVE NO. 1 AIR HOSE


    1. A01CIUN

      Remove the 2 bolts and hose clamp, and then remove the No. 1 air hose.

  8. REMOVE NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE


    1. A01CJ0J

      Disconnect the hose band.

    2. A01CGN2

      Remove the bolt.

    3. A01CIPV

      Disconnect the turbo pressure sensor connector and wire harness clamp, and remove the bolt.

    4. A01CHDR

      Disconnect the intake air temperature sensor connector.

    5. A01CJ3X

      Disconnect the hose band, and remove the No. 1 intake air pipe with No. 4 air hose.

  9. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Separate the water by-pass hose.

    2. Remove the 6 bolts and EGR cooler.

  10. REMOVE WIRE HARNESS AND CONNECTORS


    1. A01CJDO

      Disconnect the 3 connectors, 3 connector clamps and bolt.

  11. REMOVE EGR VALVE BRACKET


    1. A01CISY

      Remove the 4 bolts and bracket.

  12. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ16

      Disconnect the hoses from the EGR valve assembly.

    2. A01CJ9R

      Remove the 3 bolts, 2 union bolts, and 4 gaskets and separate the water by-pass pipe sub-assembly.

  13. REMOVE DIESEL THROTTLE BODY


    1. A01CHFJ

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH93

      Remove the 2 bolts, 2 nuts and diesel throttle body.

  14. REMOVE VENTURI ASSEMBLY


    1. Remove the 4 bolts, 2 nuts and venturi from the intake manifold.

  15. DISCONNECT FUEL HOSE


    1. A01CIXU

      Disconnect the 2 fuel hoses.

  16. REMOVE FUEL PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts and nut, and then remove the 3 fuel pipe clamps.

    2. Remove the union bolt and gaskets, and then remove the fuel pipe sub-assembly.

  17. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. Separate the wire harness connector.

    2. A01CHXB

      Separate the 2 wire harness clamps.

    3. A01CJB8

      Remove the nut and fuel pipe clamp.

    4. Using a union nut wrench (17 mm), loosen the 2 union nuts.

    5. Remove the fuel filter to injection pump fuel pipe.

  18. REMOVE FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHNN

      Remove the 2 union bolts and 5 gaskets.

    2. Remove the fuel return pipe sub-assembly.

  19. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Remove the bolt and crankshaft position sensor.

  20. REMOVE SUPPLY PUMP ASSEMBLY


    1. A01CIH3

      Separate the 2 connectors.

    2. Remove the bolt, and then separate the holder clip.

    3. A01CIHL

      Remove the 4 bolts and the supply pump assembly.

    4. Remove the O-ring from the timer cover.

  21. REMOVE INJECTION PUMP DRIVE GEAR


    1. Clamp the injection pump assembly in a vise.

    2. A01CGUZ

      Remove the 2 bolts and the timer cover.

    3. Remove the O-ring from the timer cover.

    4. A01CHKV

      Remove the nut, injection pump drive gear and crankshaft angle sensor plate.