FUEL SUPPLY PUMP(w/o Glow Plug Controller) REMOVAL

CAUTION / NOTICE / HINT

Note:

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

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

PROCEDURE

  1. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY

    Click hereClick here

  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click hereClick hereClick here

  3. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click hereClick hereClick here

  4. REMOVE NO. 1 EGR COOLER BRACKET

    Click here

  5. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note:

    After removing the fuel inlet pipe sub-assembly, cover the common rail assembly and supply pump assembly with protective tape and cover the injector inlet with protective tape or a plastic bag in order to prevent dust and foreign matter from entering.

    1. A236082

      Using a 17 mm union nut wrench, separate the union nut from the supply pump assembly while holding the supply pump assembly with a 17mm wrench.

    2. Using a 17 mm union nut wrench, remove the union nut from the common rail assembly.

    3. Remove the fuel inlet pipe sub-assembly.

  6. REMOVE SUPPLY PUMP ASSEMBLY

    1. A236084C01

      *1

      No. 1 Fuel Hose

      *2

      No. 2 Fuel Hose

      Slide the 2 clips and disconnect the No. 1 fuel hose and No. 2 fuel hose.

    2. A199697

      Disconnect the 2 connectors from the supply pump assembly.

    3. A202917C01

      *1

      Nozzle Leakage Pipe Assembly

      *2

      Fuel Hose

      Remove the retainer spring and separate the nozzle leakage pipe assembly.

    4. Slide the clip and disconnect the fuel hose.

    5. A202918

      Remove the 3 bolts and supply pump assembly.

      Note:

      When removing the supply pump assembly, make sure that the No. 1 supply pump drive coupling does not fall off, as it can be easily removed. If the No. 1 supply pump drive coupling falls off, replace it with a new one.

    6. A202920

      Remove the O-ring.

  7. REMOVE NO. 1 SUPPLY PUMP DRIVE COUPLING

    1. A202919

      Remove the No. 1 supply pump drive coupling.