FUEL SUPPLY PUMP (for DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the fuel inlet pipe, clean it with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE RADIATOR ASSEMBLY

    Click here

  3. REMOVE TIMING BELT

    Click here

  4. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

    Click here

  5. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DW4L

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

    2. A01E26N

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  6. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01DV6CE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Wiring Harness Clamp Bracket

      Detach the wire harness clamp.

    2. Remove the bolt and wiring harness clamp bracket.

  7. REMOVE NO. 2 FUEL PIPE


    1. A01DZ44

      Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.

    2. A01DWSC

      Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Supply Pump Hollow Screw
      A01E01H Fuel Check Valve
      A01DXHC Union Bolt

    3. Remove the fuel check valve, union bolt and 2 gaskets.

    4. Remove the 3 bolts and No. 2 fuel pipe.

  8. REMOVE FUEL SUPPLY PUMP ASSEMBLY


    1. Disconnect the 2 fuel hoses.

    2. Disconnect the fuel temperature sensor connector and suction control valve connector from the fuel supply pump.

    3. A01E0LPE01

      Remove the 4 bolts indicated by the arrows in the illustration.

    4. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

    5. A01E0MBE04

      Remove the set nut and O-ring while holding the crankshaft pulley using SST.

      SST
      09213-58014
      09330-00021
    6. A01DYM7

      Loosen the 2 nuts.

    7. A01DVLSE02

      Using SST, disconnect the fuel supply pump from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    8. Remove the 2 nuts and fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by the pipe.

      • The fuel supply pump must be kept horizontal.

    9. Remove the O-ring.