FUEL SUPPLY PUMP REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, 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 supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • 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 INTAKE MANIFOLD

    Click here

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. REMOVE NO. 4 AIR HOSE

    Click here

  6. REMOVE NO. 2 AIR TUBE

    Click here

  7. REMOVE NO. 1 RADIATOR HOSE

    Click here

  8. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  9. REMOVE NO. 1 OIL RESERVOIR BRACKET

    Click here

  10. REMOVE RADIATOR RESERVOIR

    Click here

  11. REMOVE FAN SHROUD

    Click here

  12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  13. REMOVE NO. 2 FUEL HOSE


    1. B003OKJ

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

  14. REMOVE NO. 1 FUEL HOSE


    1. B003S43

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

  15. REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    B003MRH

    1. Remove the fuel injection pump cover sub-assembly from the supply pump assembly.

  16. REMOVE FUEL PUMP MOTOR WIRE


    1. B003LO8

      Disconnect the fuel pump motor wire connector.

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

  17. REMOVE TIMING CHAIN COVER PLATE


    1. B003JNX

      Remove the 3 bolts and timing chain cover plate.

    2. Remove the gasket.

  18. REMOVE SUPPLY PUMP ASSEMBLY

    Note


    • B003NIOC02
      *A w/ DPF
      *B w/o DPF

      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. B003MCPC01
      *a Timing Mark

      Align the timing mark of the crankshaft pulley sub-assembly and timing chain cover by rotating the crankshaft clockwise.

    2. B003RBRC01
      *a Hold
      B003R2S 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. B003NFJC01
      *A w/ DPF
      *B w/o DPF

      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. B003QDPE01

      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

      B003P6PC01
      *a Engine Front Side
      *b Engine Rear Side
      *c SST Hexagonal Portion

      • 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.

    5. B003MSD

      w/ DPF:

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

    6. B003MWVC01
      *a Hold
      B003R2S 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
      09241-11010

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

    8. B003NXL

      Remove the O-ring from the supply pump assembly.