FUEL SUPPLY PUMP REMOVAL


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. PRECAUTION

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • Do not allow dirt and water to enter parts.

    • Make sure that there is no dirt at the connections before installing parts.

    • Air enters the fuel pipe when installing the fuel filter case. Thoroughly purge air from the fuel pipe after installation.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE EGR COOLER SUB-ASSEMBLY

    Click here

  5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove the 2 bolts, 2 cylinder head cover stays and cylinder head cover sub-assembly.

  6. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CGZM

      Disconnect the 4 connectors and remove the bolt and wire harness.

    2. Remove the cylinder head cover cushion rubber from the No. 2 cylinder head cover sub-assembly.

    3. Remove the 2 bolts, 2 cylinder head cover cushions and 2 spacers from the No. 2 cylinder head cover sub-assembly.

    4. Remove the cylinder head cover gasket and No. 2 cylinder head cover sub-assembly.

    5. Remove the 4 No. 2 cylinder head cover gaskets from the 4 injector assemblies.

  7. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CJ11E04
      Text in Illustration
      *1 Timing Mark

      Set the No. 1 cylinder to TDC/compression.

      Tech Tips


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

      • If not, turn the crankshaft 1 revolution (360°) to set the No. 1 cylinder to TDC/compression.

  8. REMOVE HARNESS BRACKET


    1. Disconnect each wire harness and clamp.

    2. A01CH1N

      Remove the bolt and harness bracket.

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01CI2D

      Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  10. REMOVE NO. 1 INTAKE PIPE

    Click here

  11. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01CISP

      Detach the 2 wire harness clamps.

    2. A01CJ77

      Remove the 2 bolts, wire harness clamp bracket and power steering suction port union.

  12. REMOVE FUEL PIPE SUB-ASSEMBLY


    1. A01CIOS

      Remove the 4 nuts and 4 fuel pipe clamps.

    2. A01CISAE02
      Text in Illustration
      *1 No. 2 Fuel Pipe
      *2 No. 3 Fuel Pipe
      *3 Fuel Hose
      *4 No. 1 Fuel Pipe
      *5 Fuel Return Pipe Sub-assembly

      Remove the 2 union bolts, 3 gaskets and No. 2 fuel pipe.

    3. Remove the 2 union bolts, 4 gaskets and No. 3 fuel pipe.

    4. Slide the clip and disconnect the No. 1 fuel pipe from the supply pump assembly.

    5. Slide the clip and disconnect the fuel hose from the fuel return pipe sub-assembly.

    6. Remove the union bolt, gasket and fuel return pipe sub-assembly.

  13. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


    1. A01CH5C

      Remove the 2 nuts and 2 fuel pipe clamps.

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

    3. Remove the fuel filter to injection pump fuel pipe sub-assembly.

      Note

      Make sure that no foreign matter or water enters the parts during the procedure.

  14. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01CIJX

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  15. REMOVE SUPPLY PUMP ASSEMBLY

    A01CHM2E01
    Text in Illustration
    *a Do not remove pipe A
    *b Do not remove pipe B

    Note


    • Do not allow dirt and water to enter parts.

    • Do not remove pipe A or B.

    • Hold the pipe not to apply load to the supply pump.

    • Do not carry the supply pump by holding the pipe.

    A01CH98E01
    Text in Illustration
    *a INCORRECT *b CORRECT

    1. Detach the wire harness clamp from the wire harness clamp bracket.

    2. Remove the bolt and wire harness clamp bracket from the injection pump stay.

    3. Disconnect the suction control valve connector and fuel temperature sensor connector.

    4. Remove the 2 bolts, nut and injection pump stay.

    5. A01CHIOE01
      Text in Illustration
      *1 Bolt
      *2 O-ring
      *3 Supply Pump

      Remove the 4 bolts and supply pump assembly.

      Note

      Make sure that no foreign matter or water enters the parts during the procedure.

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

  16. REMOVE INJECTION PUMP DRIVE GEAR


    1. Mount the injection pump drive gear in a vise between aluminum plates.

      Note


      • Do not damage the gears.

      • Make sure that no foreign matter or water enters the parts during the procedure.

    2. Loosen the nuts, and then lightly tap on the ends of the nuts with a plastic-faced hammer to detach the injection pump drive gear from the supply pump assembly.

      Note

      Do not damage the threads.

    3. A01CHKV

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

    4. A01CJCOE01
      Text in Illustration
      *1 Timer Cover
      *2 O-ring
      *3 Supply Pump
      *4 Bolt

      Remove the 2 bolts and timer cover.

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