CAUTION / NOTICE / HINT
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.
PROCEDURE
PRECAUTION
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.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
Disconnect the cables from the negative (-) main battery and sub-battery terminals.
REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)
REMOVE THERMOSTAT
REMOVE FUEL COOLER ASSEMBLY (w/o DPF)
REMOVE NO. 1 WATER BY-PASS PIPE
REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)
REMOVE TIMING GEAR COVER INSULATOR
REMOVE TIMING CHAIN COVER PLATE
Remove the 4 bolts, cover plate and gasket.
REMOVE NO. 1 FUEL PIPE
*A | w/ DPF |
*B | w/o DPF |
Remove the union bolt, fuel pipe and 2 gaskets.
REMOVE FUEL SUPPLY PUMP
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.
Remove the set nut.
Disconnect the fuel temperature sensor connector.
*A | w/ DPF |
*B | w/o DPF |
Using a 6 mm hexagon wrench, remove the bolt.
Loosen the 2 nuts.
*1 | SST (No. 1 adapter) |
*a | Service Hole |
Disconnect the pump from the supply pump drive gear.
Install SST (No. 1 adapter) to the timing chain cover.
Note
Do not use any tools in this procedure.
Rotate the supply pump gear so that the service holes are aligned with SST (No. 1 adapter) as shown in the illustration.
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.
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.
*A | w/ DPF | *B | w/o DPF |
*1 | Fuel Temperature Sensor | *2 | Suction Control Valve |
*3 | Fuel Pipe | *4 | Drive Shaft |
Remove the O-ring from the supply pump.