FUEL SUPPLY PUMP (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the engine 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.

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

  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  3. REMOVE TIMING BELT

    Click here

  4. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  5. DISCONNECT WIRE HARNESS


    1. A00JYTX

      Remove the bolt and disconnect the wire harness.

    2. A00K074

      for LHD:

      Remove the bolt and disconnect the wire harness.

    3. Detach the 5 clamps and disconnect the wire harness from the cowl top panel.

  6. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A00JZBI

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  7. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A00JW2S

      Remove the bolt and emission control valve bracket.

  8. REMOVE THROTTLE BODY BRACKET


    1. A00K044

      Remove the 3 bolts and throttle body bracket.

  9. REMOVE NO. 1 GAS FILTER


    1. A00JZLL

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  10. REMOVE GAS FILTER BRACKET


    1. A00K1HA

      Detach the clamp and disconnect the wire harness.

    2. A00K059

      Remove the bolt and gas filter bracket.

  11. REMOVE INTAKE AIR CONNECTOR


    1. A00JWYM

      Remove the 3 bolts, intake air connector and gasket.

  12. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XCX9

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A00XCYIE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  13. REMOVE NO. 2 FUEL PIPE


    1. A00JWPP

      Disconnect the fuel tube connector Click here.

      Text in Illustration
      A00JWY4 Fuel Tube Connector
      A00JYOS Union Bolt
      A00JXLB Fuel Check Valve
    2. Using a 6 mm hexagon wrench, remove the union bolt and gasket.

    3. Remove the fuel check valve, gasket and No. 2 fuel pipe.

  14. REMOVE INJECTION PUMP INSULATOR

    A00JU76
  15. REMOVE NO. 1 INJECTION PUMP PROTECTOR


    1. A00JY5C

      Remove the 2 bolts and No. 1 injection pump protector.

  16. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. Disconnect the 2 fuel hoses.

    2. Disconnect the suction control valve connector and fuel temperature sensor connector from the fuel supply pump.

    3. A00K1VXE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    4. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    5. A00JWI4E05

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    6. A00K2A3

      Loosen the 2 nuts.

    7. A00JZAIE03

      Using SST, disconnect the fuel supply pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    8. Remove the 2 nuts and fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by holding the pipe.

      • The fuel supply pump must be kept horizontal.

    9. Remove the O-ring.