FUEL SUPPLY PUMP (w/o 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 them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE TIMING BELT


    1. Remove the timing belt Click here.

  3. REMOVE INJECTOR DRIVER


    1. A01DMXG

      Disconnect the 3 connectors.

    2. Remove the 3 bolts and injector driver assembly.

  4. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01DNOM

      Remove the 3 bolts and disconnect the vane pump oil reservoir.

  5. DISCONNECT HEATER WATER PIPE SUB-ASSEMBLY


    1. A01DSEF

      Remove the bolt and disconnect the inlet heater water hose.

  6. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01DOGA

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  7. REMOVE NO. 1 INTAKE PIPE


    1. A01DN3I

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A01DNIV

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A01DQ50

      Loosen the hose clamp of the intercooler air hose.

    6. A01DMJ4

      Remove the 2 bolts and No. 1 intake pipe.

  8. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DSQX

      Remove the bolt and clamp.

    2. A01DR6BE02
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  9. REMOVE FUEL SUPPLY PUMP INSULATOR

    A01DTKY

  10. REMOVE NO. 1 FUEL SUPPLY PUMP PROTECTOR


    1. A01DQ30

      Remove the 2 bolts and No. 1 fuel supply pump protector.

  11. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01DO9D

      Disconnect the 2 fuel hoses.

    2. A01DMA3

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

    3. A01DMX0E01

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

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

    5. A01DPYKE05

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    6. A01DP6A

      Loosen the 2 nuts.

    7. A01DSTAE03

      Using SST, disconnect the fuel supply pump from the supply pump 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.

    8. Remove the 2 nuts and fuel supply pump.

      Note


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

      • The fuel supply pump must be kept horizontal.

    9. Remove the O-ring.