FUEL SUPPLY PUMP REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE ENGINE ROOM SIDE COVER


    1. A003B3G

      Remove the clip and engine room side cover.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • w/ Navigation System (for HDD):

      After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

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

  3. REMOVE NO. 1 ENGINE COVER


    1. A003DQW

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A00OSNR

      Disconnect the mass air flow meter connector.

    2. Disconnect the No. 2 ventilation hose.

    3. Disconnect the air cleaner hose.

    4. Detach the 4 clamps and remove the air cleaner cap.

  5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A00OUZE

      Remove the 3 bolts and air cleaner case.

  7. REMOVE NO. 3 FUEL HOSE


    1. A003DB7

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the No. 3 fuel hose.

  8. REMOVE NO. 1 FUEL HOSE


    1. A003C0E

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the No. 1 fuel hose.

  9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A003AJA

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  10. REMOVE FUEL HOSE PROTECTOR


    1. A003BGR

      Remove the bolt and fuel hose protector.

  11. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A003CV6

      Disconnect the exhaust fuel addition injector connector.

    2. A003BVV

      Turn the retainer as shown in the illustration.

    3. A003BLP

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A003D04E01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    5. Remove the union bolt, gasket and fuel tube.

  12. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A003EH8

      Disconnect the fuel temperature sensor connector.

    2. Disconnect the suction control valve connector.

    3. A003CYD

      Remove the 2 bolts, supply pump and supply pump drive coupling.

    4. Remove the O-ring from the supply pump.