FUEL SUPPLY PUMP REMOVAL

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.


  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.


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

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

    Click here

  4. REMOVE THERMOSTAT

    Click here

  5. REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

    Click here

  6. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A015B5OE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

  7. REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)


    1. A0159VL

      Disconnect the 3 fuel tube connectors Click here.

    2. Detach the 3 clamps and remove the fuel tube.

  8. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler)


    1. A015B15

      w/o Viscous Heater:

      Remove the 2 bolts and timing gear cover insulator.

    2. A015BZO

      w/ Viscous Heater:

      Remove the timing gear cover insulator.

  9. REMOVE TIMING CHAIN COVER PLATE

    A0156F8

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

  10. REMOVE NO. 1 FUEL PIPE


    1. A015CPXE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the union bolt, fuel pipe and 2 gaskets.

  11. REMOVE FUEL SUPPLY PUMP


    1. A015782

      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.

      Torque:
      108 N*m  { 1101 kgf*cm, 80 ft.*lbf, or more }
    2. A015BOW

      Remove the set nut.

    3. A015D0X

      Disconnect the fuel temperature sensor connector.

    4. A0155Q8E01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Using a 6 mm hexagon wrench, remove the bolt.

    5. Loosen the 2 nuts.

    6. A0155IKE03
      Text in Illustration
      *1 SST (No. 1 adapter)
      *a Service Hole

      Disconnect the pump from the supply pump drive gear.


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

        SST
        09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05031, 09955-05010 )

        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.

      • The pump must be kept horizontal.

        A015612E01
      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.