FUEL SUPPLY PUMP (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the fuel inlet pipe, clean it with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE TIMING BELT

    Click here

  3. REMOVE EGR COOLER ASSEMBLY

    Click here

  4. REMOVE VANE PUMP ASSEMBLY

    Click here

  5. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KHEI

      Disconnect the 3 fuel hoses.

    2. Remove the fuel check valve and gasket from the No. 3 nozzle leakage pipe.

      Text in Illustration
      A01KGZT Fuel Check Valve

    3. Remove the bolt and No. 2 injection pipe clamp from the No. 3 nozzle leakage pipe and No. 3 fuel pipe.

    4. Remove the bolt and No. 3 nozzle leakage pipe.

  6. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    A01KIH2

    1. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

  7. REMOVE NO. 3 FUEL PIPE

    A01KHV0
    Text in Illustration
    A01KGZT Union Bolt A01KF96 Fuel Check Valve
    A01KFFI Bolt - -

    1. Remove the 2 union bolts and gasket from the No. 3 fuel pipe.

    2. Remove the fuel check valve and gasket from the No. 3 fuel pipe.

    3. Remove the 3 bolts and No. 3 fuel pipe.

  8. REMOVE PUMP DRIVE SHAFT PULLEY


    1. A01KHRQJ01

      Remove the 4 bolts indicated by the arrows in the illustration.

    2. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

  9. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01KHLVE08

      Using SST, remove the nut and O-ring while holding the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    2. Disconnect the fuel temperature sensor connector and suction control valve connector from the fuel supply pump.

    3. Disconnect the fuel hose.

    4. A01KIHV

      Loosen the 2 nuts.

    5. A01KGXIE05

      Using SST, disconnect the fuel supply pump assembly from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    6. A01KIHV

      Remove the 2 nuts and fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by the pipe.

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring from the fuel supply pump assembly.