FUEL SUPPLY PUMP REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. 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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  4. REMOVE INTAKE MANIFOLD

    Click here

  5. REMOVE INTERCOOLER AIR HOSE

    Click here

  6. REMOVE NO. 2 INTERCOOLER AIR HOSE

    Click here

  7. REMOVE NO. 1 RADIATOR HOSE

    Click here

  8. REMOVE RADIATOR RESERVOIR ASSEMBLY

    Click here

  9. DISCONNECT NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)

    Click here

  10. REMOVE FAN SHROUD

    Click here

  11. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  12. REMOVE NO. 2 FUEL HOSE


    1. Slide the 2 clips and remove the No. 2 fuel hose from the supply pump assembly and No. 3 nozzle leakage pipe assembly.

  13. REMOVE NO. 1 FUEL HOSE

    B001EII

    1. Slide the 2 clips and remove the No. 1 fuel hose from the supply pump assembly and No. 2 fuel pipe.

  14. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    B001HVO

    1. Remove the fuel injection pump cover subassembly from the supply pump assembly.

  15. REMOVE FUEL PUMP MOTOR WIRE

    B001F3J

    1. Disconnect the fuel pump motor wire connector.

    2. Detach the clamp and remove the fuel pump motor wire.

  16. REMOVE TIMING CHAIN COVER PLATE

    B001I0W

    1. Remove the 3 bolts and timing chain cover plate.

    2. Remove the gasket.

  17. REMOVE SUPPLY PUMP ASSEMBLY

    B001DFG

    Note


    • Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.

    • With SST set, do not turn the crankshaft more than a half rotation.


    1. B001EA2E02
      Text in Illustration
      *a Timing Mark

      Align the timing mark of the crankshaft pulley subassembly and timing chain cover by rotating the crankshaft clockwise.

    2. B001HGCE02
      Text in Illustration
      *a Hold
      B001CHY Turn

      Using SST, hold the crankshaft pulley assembly and loosen the fuel supply pump shaft nut.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      Note

      Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.

      Tech Tips

      Rotate the supply pump shaft nut once to loosen it.

    3. B001IAN

      Loosen the 3 nuts from the supply pump assembly.

      Note

      Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.

    4. Install SST with 3 bolts.

      SST
      09241-11010
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Install SST with the bolts included with SST.

      Tech Tips


      • B001HLAE02

      • Make sure that the installation direction of SST is as shown in the illustration.

      • Align the hexagonal portion of SST with the supply pump shaft nut to install SST.

        Text in Illustration
        *a Engine Front Side
        *b Engine Rear Side
        *c SST Hexagonal Portion
    5. B001HDN

      Remove the 2 bolts and No. 1 fuel pump bracket from the supply pump assembly and cylinder block sub-assembly.

    6. B001EISE02
      Text in Illustration
      *a Hold
      B001CHY Turn

      Install the handle to SST. While holding the crankshaft pulley assembly in place with the crankshaft holding tool, turn the handle in the counterclockwise direction to disconnect the supply pump assembly.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      SST
      09241-11010

    7. Remove the 3 nuts and supply pump assembly from the timing chain case assembly.

    8. B001H9X

      Remove the O-ring from the supply pump assembly.