Fuel Supply Pump Removal

fuel supply pump removal (4JK1-TCY) Page 1 of 16
Fuel supply pump removal (4JK1-TCY)
1. Component views
Fuel supply pump
Part name
1. Supply pump gear nut

2. Supply pump sprocket
3. Supply pump gear
4. Fuel supply pump
Tightening torque
1: 130 N・m { 13.3 kgf・m / 96 lb・ft }
2: 25 N・m { 2.5 kgf・m / 18 lb・ft }
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2. Preliminary and post procedures
1. Preliminary procedures
1) Open the engine hood.
2) Disconnect the battery cable from the battery negative terminal.
Caution
• After turning the ignition switch (power mode for models with the passive entry and start system)
OFF, do not disconnect the battery cable within 1 minute.
• The ECM may malfunction if the battery cable is disconnected within 1 minute.
• If the battery cable is disconnected, perform the following settings after connecting the battery
negative terminal.
• Steering angle sensor setting

• Setting for front door power window switch with AUTO UP/AUTO DOWN function
3) Raise the vehicle.
3. Underguard removal
Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".
4. Coolant drain
Warning
• Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
• When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.
1) Remove the radiator cap from the radiator.
2) Loosen the radiator drain plug, and drain the coolant into a pan.
3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.
1. Drain plug
4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.
5) Tighten the drain plug on the cylinder block.
Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }
6) Tighten the radiator drain plug.
5. Cylinder head cover removal
Refer to "1.Engine 1B.Mechanical(4JK1-TCY) cylinder head cover removal".
6. EGR valve removal
Refer to "1.Engine 1H.Aux. Emission Control Devices(4JK1-TCY) EGR valve removal".
7. Fuel feed pipe removal
1) Disconnect the engine harness from the harness bracket.
2) Remove the harness bracket from the inlet manifold and common rail (fuel rail) bracket.
3) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).
Caution
• Do not reuse the fuel feed pipe.
• Cover the exposed portion to prevent foreign material from getting into the fuel system.
8. Fuel hose disconnect
1) Disconnect the fuel feed hose from the fuel supply pump.
2) Disconnect the fuel return hose from the fuel leak-off pipe.
Caution
1. Fuel feed hose

2. Fuel return hose
9. Vacuum pipe removal
1) Disconnect the fuel leak-off hose from the fuel leak-off pipe.
2) Disconnect the fuel leak-off hose from vacuum pipe A.
3) Disconnect the vacuum hose from both sides of vacuum pipe A.
4) Remove vacuum pipe A from the inlet manifold.
5) Disconnect the vacuum hose from both sides of vacuum pipe B.
6) Remove vacuum pipe B from the vacuum pipe bracket and inlet manifold.
10. Fuel leak-off pipe removal
1) Remove the fuel leak-off pipe from the fuel supply pump and common rail (fuel rail).
Caution
1. Fuel leak-off pipe
11. Injection pipe removal
1) Remove the clip from the injection pipe.
2) Remove the injection pipes from the injector and common rail (fuel rail).
Caution
• Do not reuse the injection pipe.
12. Common rail (fuel rail) removal
1) Disconnect the connector from the FRP sensor.
2) Remove the common rail (fuel rail) from the common rail (fuel rail) bracket.
Caution
• Do not hold the FRP sensor.
• Take care not to damage the connector section of the FRP sensor.
3) Remove the vacuum pipe from the common rail (fuel rail) bracket.
13. A/C compressor drive belt removal
1. Models with A/C compressor
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.
• Tension pulley
• A/C compressor
• Crankshaft pulley
1. Lock nut
2. Adjust bolt
3. A/C compressor drive belt
14. Tension pulley removal
1. Models with A/C compressor
1) Remove the tension pulley from the cylinder head.
15. Timing chain cover removal
1) Disconnect the connector from the CMP sensor.
1. CMP sensor
2) Remove the timing chain upper cover from the cylinder head.
3) Remove the noise cover from the timing chain lower cover.
4) Remove the timing chain lower cover from the gear case cover.
16. Timing chain tensioner removal
1) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to compression top
dead center.
1. Top dead center alignment mark on the gear case cover side
2. Top dead center alignment mark on the crank pulley side
2) Confirm that the camshaft and bearing cap alignment marks are aligned.
1. Alignment mark
3) Loosen the supply pump gear nut.
1. Supply pump gear nut
4) Remove the oil feed pipe from the timing chain tensioner and timing gear case.
5) Remove the timing chain tensioner and gasket from the cylinder head.
1. Oil feed pipe

2. Timing chain tensioner
3. Gasket
4. Gasket
6) Remove the timing chain tension lever pivot from the cylinder head.
17. Sprocket removal
1) Remove the nut from the sprocket.
2) Remove the sprocket from the supply pump gear.
1. Timing chain tension lever pivot

2. Sprocket
3. Nut
18. Timing chain removal
1) Referring to the diagram, remove the timing chain from the sprocket.
19. Fuel supply pump removal
1) Mark the alignment position of idle gear A and 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 temperature sensor.
4) Disconnect the connector from the FRP regulator.
1. Fuel temperature sensor connector

2. FRP regulator connector
5) Remove the fuel supply pump from the timing gear case.
Caution
• Do not hold the supply pump high-pressure pipe.
1. High pressure pipe
6) Remove the O-ring from the fuel supply pump.
1. Fuel supply pump

2. O-ring

Fuel Supply Pump Removal

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fuel supply pump removal (4JK1-TCY) Page 1 of 16

Fuel supply pump removal (4JK1-TCY)

Fuel supply pump

1. Supply pump gear nut

1: 130 N・m { 13.3 kgf・m / 96 lb・ft }

2: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2. Preliminary and post procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

• Steering angle sensor setting

3) Raise the vehicle.

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

1) Remove the radiator cap from the radiator.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

5. Cylinder head cover removal

Refer to "1.Engine 1B.Mechanical(4JK1-TCY) cylinder head cover removal".

6. EGR valve removal

Refer to "1.Engine 1H.Aux. Emission Control Devices(4JK1-TCY) EGR valve removal".

7. Fuel feed pipe removal

1) Disconnect the engine harness from the harness bracket.

8. Fuel hose disconnect

1. Fuel feed hose

9. Vacuum pipe removal

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

3) Disconnect the vacuum hose from both sides of vacuum pipe A.

4) Remove vacuum pipe A from the inlet manifold.

5) Disconnect the vacuum hose from both sides of vacuum pipe B.

10. Fuel leak-off pipe removal

1. Fuel leak-off pipe

11. Injection pipe removal

1) Remove the clip from the injection pipe.

12. Common rail (fuel rail) removal

1) Disconnect the connector from the FRP sensor.

13. A/C compressor drive belt removal

1. Models with A/C compressor

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

14. Tension pulley removal

1. Models with A/C compressor

1) Remove the tension pulley from the cylinder head.

15. Timing chain cover removal

1) Disconnect the connector from the CMP sensor.

16. Timing chain tensioner removal

3) Loosen the supply pump gear nut.

1. Supply pump gear nut

1. Oil feed pipe

17. Sprocket removal

1) Remove the nut from the sprocket.

2) Remove the sprocket from the supply pump gear.

1. Timing chain tension lever pivot

18. Timing chain removal

19. Fuel supply pump removal

3) Disconnect the connector from the fuel temperature sensor.

4) Disconnect the connector from the FRP regulator.

1. Fuel temperature sensor connector

1. High pressure pipe

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

1. Fuel supply pump

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