Fuel supply pump removal (4JJ3 without DPD)

Part name

Tightening torque

1: 10 N・m { 1.0 kgf・m / 89 lb・in }

3: 10 N・m { 1.0 kgf・m / 89 lb・in }

5: 130 N・m { 13.3 kgf・m / 96 lb・ft }

8: 50 N・m { 5.1 kgf・m / 37 lb・ft }

12: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Refer to "1.Engine 1D.Cooling(4JJ3 without DPD) radiator removal".

Refer to "1.Engine 1G.Exhaust(4JJ3 without DPD) exhaust pipe removal".

1) Remove the heat protector from the turbocharger.

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2) Disconnect the V-band from the catalytic converter.

3) Remove the catalytic converter bracket (front side) from the following parts.

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4) Remove the catalytic converter bracket (rear side) from the following parts.

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5) Remove the exhaust pipe bracket from the crankcase.

6) Remove the catalytic converter from the engine.

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1) Remove the PCV hose from the cylinder head cover and air duct.

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2) Remove the air duct from the air cleaner and turbocharger.

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1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

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1) Disconnect the connector from the MAF and IAT sensor.

2) Remove the air cleaner from the vehicle.

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1) Disconnect the EGR cooler water feed hose from the EGR cooler.

2) Disconnect the EGR cooler water return hose from the EGR cooler.

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1) Remove the upper heat protector from the EGR duct.

2) Remove the lower heat protector from the EGR duct.

3) Remove the EGR cooler and gasket from the cylinder head and exhaust manifold.

4) Remove the EGR duct and gasket from the EGR cooler.

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1) Disconnect the turbocharger water feed hose from the water feed and return pipe.

2) Disconnect the turbocharger water return hose from the water feed and return pipe.

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1) Disconnect the turbocharger oil pipe from the oil cooler and crankcase.

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1) Remove the turbocharger bracket from the cylinder block.

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1) Disconnect the connector from the turbocharger.

2) Remove the following parts as a set from the exhaust manifold.

3) Remove the turbocharger oil pipe and gasket from the turbocharger.

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4) Remove the water feed and return pipe, as well as the gasket from the turbocharger.

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

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1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the cooling fan belt from the following parts.

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1) Disconnect the B-terminal from the generator.

2) Disconnect the connector from the generator.

3) Remove the upper bracket from the generator and timing gear case.

4) Remove the generator from the lower bracket.

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

2) Remove the fan pulley from the water pump.

1) Remove the water intake pipe and water hose as a set from the oil filter and oil cooler.

1) Remove the oil filter element from the oil filter bracket using the special tool.

SST: 5-8840-0203-0 - oil filter wrench

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1) Remove the oil filter and gasket from the oil cooler.

1) Disconnect the water hose from the water intake pipe and return hose.

2) Install the EGR water pipe to the oil cooler and turbocharger lower bracket.

1) Disconnect the A/C compressor from the A/C compressor bracket.

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1) Remove the A/C compressor bracket from the cylinder head.

1) Disconnect the connector from the swirl control solenoid valve.

2) Disconnect the vacuum hose from swirl control solenoid valve.

3) Remove the swirl control solenoid valve and bracket as a set from the inlet manifold.

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1) Disconnect the fuel feed hose from the fuel supply pump.

2) Disconnect the fuel return hose from the fuel leak-off pipe.

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1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

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1) Remove the fuel leak-off pipe from the fuel supply pump and common rail (fuel rail).

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1) Remove the water pipe from the following parts.

1) Remove the tension pulley from the cylinder head.

Refer to "1.Engine 1J.Electrical(4JJ3 without DPD) starter motor removal".

1) Disconnect the connector from the boost pressure sensor.

2) Disconnect the air intake hose from the intercooler.

3) Remove the intake air duct from the intake throttle valve.

1) Remove the air duct bracket from the cylinder head cover.

1) Disconnect the connector from the injector.

2) Remove the fuel leak-off hose from the leak-off pipe.

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3) Remove the injector leak-off pipe from the injector.

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1) Disconnect the connector from the intake throttle valve.

2) Remove the following parts from the inlet manifold.

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1) Remove the glow plug terminal and glow plug connector from the glow plug.

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2) Remove the glow plug from the cylinder head.

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1) Disconnect the PCV hose from the cylinder head cover.

2) Disconnect the harness clip from the cylinder head cover.

3) Remove the harness bracket from the cylinder head cover.

4) Remove the cylinder head cover from the cylinder head.

5) Remove the oil seal from the lower side of the cylinder head cover.

1) Disconnect the connector from the CMP sensor.

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2) Remove the timing chain upper cover from the cylinder head.

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1) Remove the noise cover from the timing chain lower cover.

2) Remove the timing chain lower cover from the gear case cover.

1) Turn the crankshaft in the forward direction (clockwise) to align idle gear A side installation or removal position mark with the supply pump gear side installation or removal position mark.

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2) Remove the plug from the gear case cover.

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3) Secure the scissors gear of idle gear A using an M6 lock bolt.

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4) Install the special tool to the starter installation section of the rear plate.

SST: 5-8840-0214-0 - crankshaft stopper

5) Remove the oil feed pipe from the timing chain tensioner.

6) Remove the timing chain tensioner and gasket from the cylinder head.

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7) Remove the oil feed pipe from the cylinder block.

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8) Remove the timing chain lever pivot from the timing chain tension lever.

9) Remove the idle gear D center bolt and sleeve from the idle gear D shaft.

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10) Remove the idle gear D sprocket and timing chain as a set from idle gear D and the supply pump gear sprocket.

1) Remove the supply pump sprocket from the supply pump gear.

2) Remove the supply pump gear from the fuel supply pump using a gear puller.

3) Disconnect the connector from the fuel supply pump.

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4) Remove the fuel supply pump from the timing gear case.

5) Remove the O-ring from the fuel supply pump.

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