CAUTION / NOTICE / HINT
Note
When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.
Replaced Parts (A) | Pipes Requiring New Replacement |
---|---|
|
|
|
|
|
|
After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.
The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.
Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.
Make sure foreign matter does not enter the fuel path.
PROCEDURE
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.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
REMOVE INTAKE MANIFOLD
REMOVE NO. 1 ENGINE UNDER COVER
REMOVE NO. 4 AIR HOSE
REMOVE NO. 2 AIR TUBE
REMOVE NO. 1 RADIATOR HOSE
DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY
REMOVE NO. 1 OIL RESERVOIR BRACKET
REMOVE RADIATOR RESERVOIR
REMOVE FAN SHROUD
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
REMOVE NO. 2 FUEL HOSE
Slide the 2 clips and remove the No. 2 fuel hose from the supply pump assembly and No. 3 nozzle leakage pipe assembly.
REMOVE NO. 1 FUEL HOSE
Slide the 2 clips and remove the No. 1 fuel hose from the supply pump assembly and No. 2 fuel pipe.
REMOVE NO. 4 FUEL PIPE (w/ Pressurized Fuel Filter)
Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.
REMOVE FUEL INJECTION PUMP COVER SUB-ASSEMBLY
Remove the fuel injection pump cover sub-assembly from the supply pump assembly.
REMOVE FUEL PUMP MOTOR WIRE
Disconnect the fuel pump motor wire connector.
Detach the clamp and remove the fuel pump motor wire.
REMOVE TIMING CHAIN COVER PLATE
Remove the 3 bolts and timing chain cover plate.
Remove the gasket.
REMOVE SUPPLY PUMP ASSEMBLY
Note
*A | w/ DPF and Pressurized Fuel Filter |
*B | w/o Pressurized Fuel Filter |
Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.
With SST set, do not turn the crankshaft more than a half rotation.
*a | Timing Mark |
Align the timing mark of the crankshaft pulley sub-assembly and timing chain cover by rotating the crankshaft clockwise.
*a | Hold |
Turn |
Using SST, hold the crankshaft pulley assembly and loosen the fuel supply pump shaft nut.
Note
Do not excessively loosen the supply pump shaft nut, otherwise SST cannot be installed.
Tech Tips
Rotate the supply pump shaft nut once to loosen it.
*A | w/ DPF and w/ Pressurized Fuel Filter |
*B | w/o Pressurized Fuel Filter |
Loosen the 3 nuts from the supply pump assembly.
Note
Do not completely remove the nuts. Otherwise, the supply pump assembly may fall off.
Install SST with 3 bolts.
Note
Install SST with the bolts included with SST.
Tech Tips
*a | Engine Front Side |
*b | Engine Rear Side |
*c | SST Hexagonal Portion |
Make sure that the installation direction of SST is as shown in the illustration.
Align the hexagonal portion of SST with the supply pump shaft nut to install SST.
w/ DPF or Pressurized Fuel Filter:
Remove the 2 bolts and No. 1 fuel pump bracket from the supply pump assembly and cylinder block sub-assembly.
*a | Hold |
Turn |
Install the handle to SST. While holding the crankshaft pulley assembly in place with the crankshaft holding tool, turn the handle in the counterclockwise direction to disconnect the supply pump assembly.
Remove the 3 nuts and supply pump assembly from the timing chain case assembly.
Remove the O-ring from the supply pump assembly.