FUEL SUPPLY PUMP INSTALLATION


  1. INSTALL INJECTION PUMP DRIVE GEAR


    1. Install a new O-ring onto the timer cover.

    2. A01CGUZ

      Install the timer cover onto the injection or supply pump with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    3. A01CHKV

      Install the crankshaft angle sensor plate and the drive gear with the nut.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  2. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A01CH8BE01

      Turn the drive gear and align the hole with the matchmark as shown in the illustration.

    2. Install a new O-ring onto the timer cover.

    3. A01CI5SE01

      Align the matchmarks of the timer cover and the front end plate, then install the supply pump.

    4. A01CHOV

      When the crankshaft position sensor's installation hole can be accessed directly:


      1. Check that the knock pin of the injection pump drive gear is at the center of the hole. Then, proceed to step (f).

        If not, perform steps (b) and (c) again.

    5. A01CH68E01

      When the crankshaft position sensor's installation hole can not be accessed directly:


      1. Tape the screwdriver as shown in the illustration.

      2. A01CIOU

        Remove the service plug from the timing chain or belt cover sub-assembly.

      3. A01CJEHE01

        Insert the screwdriver into the service plug hole.

      4. Check that the tape end and timing chain or belt cover sub-assembly are aligned as shown in the illustration.

        If not, perform steps (b) and (c) again.

      5. Install the service plug hole.

    6. A01CGZX

      Install the injection or supply pump with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    7. A01CIH3

      Install the holder clip with the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    8. Connect the 2 connectors.

  3. INSTALL CRANK POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the sensor.

    2. A01CI7B

      Install the crank position sensor with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Connect the crank position sensor connector.

  4. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJ7V

      Temporarily install the fuel pipe with the union nuts.

    2. Using SST, tighten the union nuts.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

      Note

      Refer to the torque above when not using SST. When using SST, calculate the torque in accordance with the lengths of SST and the torque wrench. Click here

    3. Install the pipe clamp with the nut. Tighten the nut until the clamp's edges make contact with the engine side clamp's edges.

  5. INSTALL FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CIXS

      Install a new gasket and the fuel return pipe with the union bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    2. Install the fuel pipe clamp with the nut. Tighten the nut until the clamp's edges make contact with the engine side clamp's edges.

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01CJ4U

      Install 4 new gaskets and the No. 4 fuel pipe with the 2 union bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf, for M10 bolt }
      25 N*m  { 250 kgf*cm, 18 ft.*lbf, for M12 bolt }

  7. INSTALL FUEL DELIVERY PIPE


    1. A01CICS

      Install 2 new gaskets and the fuel delivery pipe with the union bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  8. CONNECT FUEL RETURN HOSE


    1. A01CJ15

      Connect the fuel hose.

  9. INSTALL OIL SEPARATOR ASSEMBLY


    1. A01CGOXE01

      Install the oil separator bracket with the 4 bolts onto the oil separator.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    2. A01CH8V

      Connect the 3 hoses.

    3. Install the oil separator assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CHCD

      Install the harness bracket with the 2 bolts onto the oil separator.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  10. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. Install the ventilation pipe sub-assembly with the 2 bolts.

    2. Connect the 3 hoses.

  11. INSTALL WIRE HARNESS AND CONNECTORS


    1. A01CH2B

      Connect the 3 connectors.

  12. INSTALL INTAKE AIR PIPE NO. 1 WITH AIR HOSE NO. 4


    1. A01CILLE01

      Install the No. 1 intake air pipe with No. 4 air hose with the hose band.

    2. A01CHYE

      Install the bolt, and connect the intake air temperature sensor connector.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
    3. A01CHLBE01

      Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
    4. A01CGQKE01

      Install the bracket with the 2 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
    5. A01CIMYE01

      Install the hose band.

  13. BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    Click here.

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  15. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      2. Connect the intelligent tester to the DLC3.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Select the following menu items: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizing common rail internal fuel pressure, and checking for fuel leaks Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected

        • Above conditions preserved while test is ON

  16. INSPECT FOR OIL LEAK

  17. INITIALIZE FUEL PUMP

    Tech Tips

    Click here.