FUEL PUMP(for High Pressure) REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. PRECAUTION

    Note

    After turning the engine switch off, waiting time maybe required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notice before proceeding with work.

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  4. REMOVE INTAKE MANIFOLD

    Click here

  5. REMOVE NO. 3 WATER BY-PASS PIPE


    1. B003UP5

      Slide the 2 clips and disconnect the inlet heater water hose A and outlet heater water hose A from the No. 3 water by-pass pipe.

    2. Disengage the wire harness clamp from the No. 3 water by-pass pipe.

    3. Remove the bolt.

    4. Slide the 2 clips and disconnect the No. 8 water by-pass hose, No. 9 water by-pass hose and remove the No. 3 water by-pass pipe.

  6. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here

  7. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B003TWT

      Slide the clip and disconnect the No. 3 fuel hose from the No. 1 fuel pipe sub-assembly.

    2. A01MXGL

      Slide the clip and disconnect the No. 1 fuel hose from the fuel relief valve assembly.

    3. Slide the clip and disconnect the No. 2 fuel hose from the fuel pump assembly.

    4. Remove the 2 bolts and No. 1 fuel pipe sub-assembly.

  8. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Disconnect the fuel pump connector.

    2. B003VSTC04
      *a 19 mm Union Nut Wrench
      *b Hold
      *c Turn

      Using a 21 mm wrench, secure the union bolt on the fuel pump side in place. Using a 19 mm union nut wrench, loosen the union nut and remove the No. 2 fuel pipe sub-assembly.

      Note


      • There must be absolutely no free play in the union bolt on the fuel pump assembly side.

      • If the union bolt on the fuel pump assembly side has free play, replace the fuel pump assembly.

    3. A01MVUZ

      Remove the 2 bolts on the fuel delivery pipe sub-assembly side.

      Note


      • Do not remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly. Only remove the 2 bolts.

      • If the No. 2 fuel pipe sub-assembly is accidentally removed, replace its O-ring, No. 1 back-up ring and No. 2 back-up ring.

  9. REMOVE FUEL PUMP ASSEMBLY


    1. B003X65

      Remove the 2 nuts, fuel pump assembly and fuel pump insulator from the cylinder head sub-assembly.

  10. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. A01MWXE

      Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly.

      Note

      Pull and remove the No. 2 fuel pipe sub-assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe sub-assembly O-ring.

    2. Remove the O-ring, No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and E-ring from the No. 2 fuel pipe sub-assembly.