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. 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 NO. 1 ENGINE COVER


    1. A00ORGX

      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. A010OJ5

      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. A010O7W

      Remove the 3 bolts and air cleaner case.

  7. REMOVE NO. 3 FUEL HOSE


    1. A00OTCD

      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. A00OTLN

      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. A00OT1T

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

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

  10. REMOVE FUEL HOSE PROTECTOR


    1. A00OUIW

      Remove the bolt and fuel hose protector.

  11. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A00OU7J

      Disconnect the exhaust fuel addition injector connector.

    2. A00OU58

      Turn the retainer as shown in the illustration.

    3. A00ORLS

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A00OTGY

      Remove the check valve and gasket.

      Text in Illustration
      A00OVAR Check Valve

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

  12. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A00OQUH

      Disconnect the fuel temperature sensor connector.

    2. Disconnect the suction control valve connector.

    3. A00OVCA

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

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