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FUEL SUPPLY PUMP REMOVAL

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CAUTION / NOTICE / HINT

Note:

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

  • w/ DPF:

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

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PROCEDURE


  1. Click here

    PRECAUTION

    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).

  2. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  3. Click here

    REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

    (Click here)

  4. Click here

    REMOVE THERMOSTAT

    (Click here)

  5. Click here

    REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

    (Click here)

  6. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  7. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)

    Click here

  8. Click here

    REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)

    Click here

  9. Click here

    REMOVE TIMING CHAIN COVER PLATE


    1. Remove the 4 bolts, cover plate and gasket.

  10. Click here

    REMOVE NO. 1 FUEL PIPE


    1. B001Y38E02

      Remove the union bolt, fuel pipe and 2 gaskets.

      Table 1. Text in Illustration
      *A w/ DPF
      *B w/o DPF
  11. Click here

    REMOVE FUEL SUPPLY PUMP


    1. B001W4S

      Using a wrench, hold the crankshaft.

      Note:

      Do not turn the crankshaft counterclockwise.

      If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt (Click here).

      108 N*m 1101 kgf*cm 80 ft.*lbf
      or more
    2. B001WJ8

      Remove the set nut.

    3. B001WF9

      Disconnect the fuel temperature sensor connector.

    4. B001WOAE02

      Using a 6 mm hexagon wrench, remove the bolt.

      Table 2. Text in Illustration
      *A w/ DPF
      *B w/o DPF

    5. Loosen the 2 nuts.

    6. B001Y0QE04

      Disconnect the pump from the supply pump drive gear.


      1. Install SST (No. 1 adapter) to the timing chain cover.

        09950-50013 09951-05010 09952-05010 09953-05020 09954-05031 09955-05010
        Table 3. Text in Illustration
        *1 SST (No. 1 adapter)
        *a Service Hole
        Note:

        Do not use any tools in this procedure.

      2. Rotate the supply pump gear so that the service holes are aligned with SST (No. 1 adapter) as shown in the illustration.

      3. Using SST, disconnect the pump from the supply pump drive gear.

        Note:

        • When removing or installing SST, do not push the supply pump gear.

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

    7. Remove the 2 nuts.

      Note:

      • Do not hold the supply pump by the parts indicated by the arrows in the illustration, as this may result in deformation, damage and fuel leakage.

      • B001Y4ZE02

        The pump must be kept horizontal.

      Table 4. Text in Illustration
      *A w/ DPF *B w/o DPF
      *1 Fuel Temperature Sensor *2 Suction Control Valve
      *3 Fuel Pipe *4 Drive Shaft

    8. Remove the O-ring from the supply pump.