FUEL SUPPLY PUMP REMOVAL


  1. DISCONNECT BATTERY NEGATIVE TERMINAL

    Note


    • When removing the injection pipes and fuel inlet pipe, clean them up with a brush and compressed air.

    • When installing, clean up the seal surface of the injector, injection pipe, fuel inlet pipe, supply pump and common rail with clean light oil.

    • When replacing the common rail and/or injectors, it is necessary to replace injection pipes, as well.

    • When replacing the injection pump and/or common rail replaced, it is necessary to replace fuel inlet pipe, as well.

  2. REMOVE FRONT SEAT ASSEMBLY RH (W/O TILT CAB CAB TYPE)

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  3. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)

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  4. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Remove the clip and nut, and then Disconnect the select cable from the transmission.

  5. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Remove the clip and nut, and then Disconnect the shift cable from the transmission.

  6. DISCONNECT TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)

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  7. DISCONNECT PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

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  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Remove the front door scuff.

    2. Remove the floor mat.

    3. Remove the 7 bolts and engine service hole sub cover.

  9. DISCONNECT ENGINE WIRE

  10. REMOVE TIMING BELT NO.1 COVER

  11. REMOVE PUMP DRIVE SHAFT PULLEY

  12. REMOVE DIESEL THROTTLE BODY ASSEMBLY

  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01KICG

    1. Remove the bolt and injection pipe clamp No. 2.

    2. Using a union wrench 17mm, loosen the fuel inlet union of common rail side.

    3. Using a union wrench 17 mm, loosen the fuel inlet pipe union of pump side.

    4. Remove the inlet pipe sub-assembly.

      Note

      After removing the fuel pipe, affix the gum tape to the pump, common rail, and the whole injector installation area of the cylinder head cover for preventing dust.

  14. REMOVE INSTALL INJECTION PUMP ASSEMBLY

    A01KFBF

    1. Disconnect the 2 connectors from the injection pump.

    2. Remove the bolt and stay from the injection pump assembly.

    3. Disconnect the fuel hose from the injection pump assembly.

    4. A01KID0E01
      Text in Illustration
      *a Hold

      Hold the crankshaft pulley, and remove the injection pump drive gear set nut.

      Note

      Do not turn the crankshaft pulley. The valve heads will hit against the piston top.

    5. Remove the O-ring from the injection pump drive gear.

    6. A01KFJO

      Remove the 2 nuts holding the injection pump to the timing gear case.

    7. A01KEA6E01

      Remove the Injection Pump.

      SST
      09950-40011   ( 09957-04010 )
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

      Note


      • Tighten the 2 bolts more then 8 mm (0.31 in.).

      • Set SST so that it is balanced.

      • Do not hold or carry the injection pump by the adjusting lever.

      • Do not put the injection pump at an angle more than 45 from the horizontal.