FUEL SUPPLY PUMP REMOVAL

Note


  • 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 WITH NO. 2 EGR VALVE ASSEMBLY (w/ DPF)

    Click here

  4. REMOVE EGR COOLER ASSEMBLY (w/o DPF)

    Click here

  5. REMOVE VANE PUMP ASSEMBLY

    Click here

  6. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)


    1. A003AI6E01

      Disconnect the 3 fuel hoses.

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

    3. Remove the fuel check valve and gasket.

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

  7. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. A003F3C

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

  8. REMOVE NO. 3 FUEL PIPE (w/ DPF)

    Tech Tips

    It is not necessary to completely remove the No. 3 fuel pipe from the vehicle.


    1. for Engine LH Side:


      1. Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      2. Remove the fuel check valve and gasket.

      3. Remove the bolt.

    2. for Engine Rear Side:


      1. Remove the union bolt and gasket.

      2. Remove the 2 bolts.

        A003C66E01

  9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY (w/o DPF)


    1. A003BH2E01

      Remove the bolt and No. 2 injection pipe clamp.

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

      Note

      If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.

    3. A003CA9

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

  10. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. w/ DPF:

      Disconnect the fuel hose.

    2. w/o DPF:

      Disconnect the 2 fuel hoses.

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

    4. A003GEBE01

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

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

    6. A003EOBE04

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

      SST
      09213-58014
      09330-00021
    7. A003AI0

      Loosen the 2 nuts.

    8. A003B2KE02

      Using SST, disconnect the fuel supply pump 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.

    9. 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.

    10. Remove the O-ring.