Injetor pump removal for 1hz diesel

Removing and reinstalling the injector pump on a Hino Dutro SO5D engine requires careful attention to detail to avoid damaging the components. Here's a general guide on how to perform this task:
Tools and Materials Needed:

• Basic mechanic's toolset
• Replacement gaskets and seals (if necessary)
• Clean rags
• Diesel fuel-safe sealant (if necessary)
• Torque wrench

Procedure:

1. Prepare the Engine:
   • Park the vehicle on a flat, level surface and engage the parking brake.
   • Disconnect the negative terminal of the battery to prevent accidental starting.
   • Remove any components obstructing access to the injector pump, such as air intake hoses or covers.
2. Drain the Fuel System:
   • Relieve the fuel pressure in the system by loosening the fuel line fittings at the injector pump and allowing any residual pressure to escape.
   • Place a suitable container underneath to catch any spilled fuel.
   • Disconnect the fuel lines from the injector pump.
3. Disconnect Electrical Connections:
   • Disconnect any electrical connections, such as wiring harness connectors or sensor connections, from the injector pump.
4. Remove the Injector Pump:
   • Loosen and remove the mounting bolts securing the injector pump to the engine block. Take note of their locations and lengths as they may vary.
   • Carefully lift the injector pump away from the engine, ensuring not to damage any surrounding components.
   • Place the injector pump on a clean work surface.
5. Install the New Injector Pump:
   • Position the new injector pump in place on the engine block, aligning it with the mounting holes.
   • Install and tighten the mounting bolts to the specified torque settings. Refer to the manufacturer's specifications for the correct torque values.
   • Reconnect any electrical connections and fuel lines to the injector pump.
6. Reassemble Components:
   • Reinstall any components that were removed to access the injector pump, such as air intake hoses or covers.
   • Ensure all connections are properly secured and tightened.
7. Refill the Fuel System:
   • Prime the fuel system to remove any air by using the vehicle's priming mechanism or manually bleeding the system.
   • Check for any fuel leaks around the injector pump and fuel lines.
8. Test Operation:
   • Reconnect the negative terminal of the battery.
   • Start the engine and monitor for any abnormal noises or vibrations from the injector pump.
   • Verify that the engine runs smoothly and there are no fuel leaks.

I feel it is likely to be the injectors squirting the the diesel instead of atomising it. You could try a bottle of Injector cleaner in the tank. There is one just for Toyotas

https://www.google.com/search?q=diesel+injector+cleaner&

This is a good review of the products

https://www.cnet.com/roadshow/news/best-fuel-injector-cleaner/


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diesel pump
follow the pipes from injector that will lead you to fuel pump.
you will have to take fuel line off from injector so it make it easy to remove them from pump...
4 bolts and pump is out

Air leak in the fuel line? All the lines are pressurised to some degree.
Do you mean it was sucking air on the tank to pump side?
Because its a diesel and you have white smoke and a misfire you need specialist help to identify which injector is playing up. White smoke is usually excess fuel or incomplete firing on that cylinder. Toyota lumps are very reliable so get some help, a good diesel mechanic would have a clip on tester that would check each cylinder.
At 2002 I'm surprised there is a fuel problem but you don't give mileage so an injector is the best guess.

sounds like the injector sleeve O rings have failed this was common.
if you put a clear plastic piece of hose on supply line for diesel fuel filter to head fitting at front and fuel is not black but normal diesel colour thats good.
then put clear hose on return line fitting at rear of cylinder head and fuel is now darker, engine oil is by passing injector sleeve top O rings and entering into fuel gallery in head.
rocker cover, injector rail, injectors need removing and injector sleeves need replacing as well as O rings and seats.
a special tool is needed to remove the injector sleeves out of the head. you will also need to drain the cooling system before removing the injector sleeves, so coolant is also needed.
dealers have special tool for injector sleeves

how do i change a diesel pump on a sprinter bus

better chec the wiring or connections 1st--pull the plug from the pump and inspect for flaws and corrosion then plug back in--pump itself can be tested--the fuel injection pump in engine area may have issues

thoroughly clean area around injectors,and then blow with compressed air so no bits will fall in the holes when injectors removed.loosen main injector pipe nut,remove return fuel line,dont lose copper washers,put special fuel bolts back in top of injector firm[by hand] undo holding down bolts evenly,undo fully injector pipe nut,.gently pry injector loose,and remove,making sure sealing washer at bottom also comes out..while I dont specifically know this particular engine,this guide applies to most diesel motors.I have rebuilt a 6v72 detroit motor,yrs ago.Assembly is reversal.may need to crank over to bleed diesel at injector,always use new sealing washers.

Hi, I hope this helps...

1994-96 Engines
See Figures 3 and 4



Fig. Fig. 3: Details of the fuel pump assembly-1994-96 diesel engine



Fig. Fig. 4: View of the fuel pump-1994-96 diesel engine

1. Remove the turbocharger assembly.
2. Remove the fuel line banjo bolt at the pump.
3. Remove the fuel line fittings at the rear of the cylinder heads.
4. Remove the fuel lines assembly.
5. Loosen the two hose clamps at the fuel pump fittings.
6. Disconnect the water drain hose at the fuel filter.
7. Disconnect the filter and position it forward.
8. Remove the fuel pump retaining bolts, then lift the pump out of the crankcase bore.
9. Remove the fuel pump tappet from the crankcase bore.

To install:

1. Rotate the engine so the fuel pump eccentric is on the base circle.
2. Install the fuel pump tappet in the base of the fuel pump.
3. Replace the O-ring on the fuel pump base.
4. Install the fuel pump and bolt it in place.
5. Install the fuel filter and connect the water drain hose.
6. Connect the two fuel hoses at the front of the fuel pump.
7. Tighten the fuel line clamps and install the fuel filter retaining bolts.
8. Install the fuel line assembly and new seal rings at the rear of the pump.
9. Loosely install the fuel line fittings at the rear of the cylinder heads.
10. Install the fuel line banjo fitting at the pump. Tighten the fitting to 40 ft. lbs. (54 Nm).
11. Tighten the fuel line fittings.
12. Install the turbocharger assembly.

Visited Local Diesel Pump Expert He Diagnosed Worn Injector Pump