FUEL SUPPLY PUMP REMOVAL


  1. REMOVE ENGINE W/ TRANSAXLE

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  2. REMOVE TIMING BELT UPPER COVER


    1. A0138DM

      Remove the 5 bolts and timing belt upper cover.

  3. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0136UU

      Using a "torx" socket wrench, remove the 3 screws.

    2. Remove the air cleaner cap sub-assembly.

    3. Remove the air filter element.

  4. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. A0136RX

      Disconnect the intake air temperature sensor connector.

    2. A0137XK

      Loosen the air hose No.2 clamp.

    3. Using a "torx" socket wrench, remove the screw.

    4. Remove the bolt, intake air resonator and O-ring.

  5. REMOVE TURBO PRESSURE SENSOR


    1. A0137YA

      Disconnect the turbo pressure sensor connector.

    2. A0136M9

      Disconnect the turbo pressure sensor hose from the cylinder head cover.

    3. A01362M

      Remove the bolt and turbo pressure sensor.

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A0137UK

      Loosen the air hose No.1 clamp.

    2. Disconnect the PCV hose from the cylinder head cover.

    3. Using a "torx" socket wrench, remove the 2 screws.

    4. Remove the air cleaner case sub-assembly.

  7. REMOVE FUEL FILTER ASSEMBLY


    1. A0135ZW

      Disconnect the fuel return hose from the No.4 injector.

    2. A0135W0

      Disconnect the fuel temperature sensor connector.

    3. A0137NS

      Pinch the retainer as illustrated, then pull out the fuel hose from the fuel pump.

    4. Pinch the retainer as illustrated, then pull out the fuel return hose from the fuel pump.

    5. A013931

      Disconnect the fuel level warning switch connector.

    6. A01393H

      Disconnect the fuel heater hose connector (w/ fuel heater).

    7. A0136XL

      Using a "torx" socket wrench, remove the screw.

    8. Remove the 2 bolts, fuel filter, and fuel bracket with priming pump.

  8. DISCONNECT ENGINE WIRE NO.2


    1. A0138A5

      Disconnect the glow harness connector.

    2. A0135V2

      Disconnect the fuel pressure sensor connector.

    3. A0136C6

      Disconnect the 4 injector connectors and remove the engine wire No.2.

  9. REMOVE HEATER WATER OUTLET HOSE A


    1. A0137MH

      Using pliers, slide the clip to remove the heater water outlet hose A.

  10. REMOVE EGR COOLER WATER BY-PASS HOSE


    1. A0137WQ

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the water by-pass hose.

  11. REMOVE EGR VALVE ASSEMBLY


    1. A0136XY

      Disconnect the EGR valve connector.

    2. A0137SF

      Using a "torx" socket wrench, remove the 2 screws.

    3. A0136D4

      Remove the bolt and clamp from the EGR pipe.

    4. A01369N

      Remove the 2 bolts from the EGR valve.

    5. Remove the EGR valve assembly, gasket and O-ring.

  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A013789

      Disconnect the diesel throttle valve connector.

    2. A0136DL

      Remove the 10 bolts, cylinder head cover sub-assembly, gasket and 4 O-rings.

  13. REMOVE V-RIBBED BELT TENSIONER SUB-ASSEMBLY


    1. A0137H7

      Remove the 3 bolts and V-ribbed belt tensioner sub-assembly.

  14. REMOVE CRANKSHAFT PULLEY


    1. A0137L7E01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Remove the bolt and crankshaft pulley.

  15. REMOVE TIMING BELT LOWER COVER


    1. A0135SJ

      Remove the 5 bolts and timing belt lower cover.

  16. REMOVE ENGINE MOUNT BRACKET


    1. A01374V

      Remove the 4 bolts and engine mount bracket.

  17. SET TIMING MARK


    1. A0136BR

      Using the crankshaft pulley bolt, turn the crankshaft so that the timing holes of the crankshaft timing pulley and the oil pump are aligned.

    2. A0137V1

      Check that the timing holes of the camshaft drive pulley and the cylinder head are aligned.

  18. REMOVE CRANK POSITION SENSOR


    1. A0136ZP

      Disconnect the crank position sensor connector.

    2. Remove the bolt and crank position sensor.

    3. Remove the bolt and crankshaft timing pulley support.

  19. REMOVE TIMING BELT


    1. A0135VS

      Remove the bolt and timing belt tensioner.

    2. Remove the timing belt.

  20. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A0136SBE01

      Using SST, loosen the union nuts and remove the injection pipe.

      SST
      09023-38401
      09023-12701

      Note

      While holding the union on supply pump using a wrench, loosen the union nut on the injection pipe.

    2. A013749

      Disconnect the 2 connectors.

    3. A0137E3E01

      Pinch the tube connectors and then pull out the fuel tubes.

      Note


      • Check if there is any dirt around the connectors before this operation and remove the dirt as necessary.

      • Remove the quick connectors by hand.

      • Do not damage the disconnected pipe and connector. Prevent intrusion of foreign objects by covering them with plastic bags.

      • If the pipe and the connector are stuck, try wiggling or pushing and pulling the connector to release it. Pull the connector off of the pipe carefully.

    4. A01390Z

      Remove the 2 bolts, nut, and bracket.

    5. A0138CZE01

      Using SST, loosen the nut.

      SST
      09960-10010   ( 09962-01000 )
    6. A01367YE01

      Using SST, separate the supply pump gear.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04010, 09954-04010, 09955-04061 )

    7. Remove the nut and supply pump gear.

    8. A0138GH

      Remove the 3 bolts and supply pump assembly.