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FUEL SUPPLY PUMP REMOVAL

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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.

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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 (Click here).

  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 (Click here).

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    REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear of the No. 1 engine cover. Continue to raise the No. 1 engine cover to detach the 3 clips on the front and side of the No. 1 engine cover and remove the No. 1 engine cover.

      Note:

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

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    REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01IOT2

      Detach the clamp and disconnect the mass air flow meter connector.

    2. Slide the clamp and disconnect the PCV hose from the cylinder head cover sub-assembly.

    3. Slide the clamp and disconnect the air cleaner hose assembly from the turbocharger sub-assembly.

    4. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  5. Click here

    REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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    REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01ITZL

      Remove the 3 bolts and air cleaner case.

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    REMOVE NO. 3 FUEL HOSE


    1. A01IQ1E

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the No. 3 fuel hose from the fuel supply pump assembly and No. 2 nozzle leakage pipe.

  8. Click here

    REMOVE NO. 1 FUEL HOSE


    1. A01ISIB

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the No. 1 fuel hose from the fuel supply pump assembly and fuel filter assembly.

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    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. A01ITN1

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

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

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    REMOVE FUEL HOSE PROTECTOR


    1. A01INWG

      Remove the bolt and fuel hose protector.

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    REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A01IT57

      Disconnect the exhaust fuel addition injector connector.

    2. A01IQ6B

      Turn the retainer as shown in the illustration.

    3. A01IUL8

      Disconnect the fuel tube sub-assembly from the exhaust fuel addition injector assembly.

    4. A01INMW

      Remove the check valve and gasket.

      Table 1. Text in Illustration
      A01ISER Check Valve

    5. Remove the union bolt, gasket and fuel tube sub-assembly.

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    REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. A01IOEP

      Disconnect the fuel temperature sensor connector.

    2. Disconnect the suction control valve connector.

    3. A01IQWG

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

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