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FUEL SUPPLY PUMP REMOVAL

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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.

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PROCEDURE


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    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.

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  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.

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  3. Click here

    REMOVE INTAKE MANIFOLD

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  4. Click here

    REMOVE NO. 1 ENGINE UNDER COVER

  5. Click here

    REMOVE NO. 4 AIR HOSE

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  6. Click here

    REMOVE NO. 2 AIR TUBE

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  7. Click here

    REMOVE NO. 1 RADIATOR HOSE

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  8. Click here

    DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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  9. Click here

    REMOVE NO. 1 OIL RESERVOIR BRACKET

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  10. Click here

    REMOVE RADIATOR RESERVOIR

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  11. Click here

    REMOVE FAN SHROUD

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  12. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  13. Click here

    REMOVE NO. 2 FUEL HOSE


    1. B0028WS

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

  14. Click here

    REMOVE NO. 1 FUEL HOSE


    1. B0025A6

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

  15. Click here

    REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY


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

  16. Click here

    REMOVE FUEL PUMP MOTOR WIRE


    1. B0024JS

      Disconnect the fuel pump motor wire connector.

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

  17. Click here

    REMOVE TIMING CHAIN COVER PLATE


    1. B0025TV

      Remove the 3 bolts and timing chain cover plate.

    2. Remove the gasket.

  18. Click here

    REMOVE SUPPLY PUMP ASSEMBLY

    Note:
    • B0024BVC02
      *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. B00265TC01
      *a Timing Mark

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

    2. B0026EVC01
      *a Hold
      B0068HS Turn

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

      09213-58014 91551-80840
      09330-00021
      Note:

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

      Tip:

      Rotate the supply pump shaft nut once to loosen it.

    3. B00288QC01
      *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. B0028CVE01

      Install SST with 3 bolts.

      09241-11010
      10 N*m 102 kgf*cm 7 ft.*lbf
      Note:

      Install SST with the bolts included with SST.

      B00261HC01
      *a Engine Front Side
      *b Engine Rear Side
      *c SST Hexagonal Portion
      Tip:

      • 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. B0027YM

      w/ DPF:

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

    6. B0027ZYC01
      *a Hold
      B0068HS 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.

      09213-58014 91551-80840
      09330-00021
      09241-11010

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

    8. B0026GY

      Remove the O-ring from the supply pump assembly.