FUEL SUPPLY PUMP INSTALLATION


  1. INSTALL INJECTION PUMP ASSEMBLY

    A01KIG7

    Note

    Do not put the injection pump at an angle more than 35°from the horizontal.


    1. Install a new O-ring to the pump.

    2. Apply a light coat of engine oil on the O-ring.

    3. Align the set key on the drive shaft and groove of the injection pump drive gear.

    4. A01KEA7

      Temporality install the injection pump assembly with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    5. Remove the gum tape from the fuel pipe.

    6. A01KID0E01
      Text in Illustration
      *a Hold

      Install the injection pump drive gear set nut.

    7. Hold the crankshaft pulley, and torque the nut.

      Torque:
      63.6 N*m  { 648 kgf*cm, 47 ft.*lbf }

      Note

      Do not turn the crankshaft pulley. The valve heads will hit against the piston top.

    8. Check the thrust clearance of the injection pump drive shaft.

    9. A01KIKN

      Connect the fuel hose to the injection pump.

  2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01KICG

    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. Using a union wrench 17 mm, tighten the fuel inlet pipe sub-assembly union of common rail side.

      Torque:
      31.9 N*m  { 325 kgf*cm, 23 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in)..

    3. Using a union wrench 17 mm, tighten the fuel inlet pipe sub-assembly union of injection pump side.

      Torque:
      31.9 N*m  { 325 kgf*cm, 23 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    4. Install the injection pipe clamp to the fuel inlet pipe sub- assembly.

      Tech Tips

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in)..

  3. BLEED INJECTION PIPE


    1. Move the priming pump of the fuel filter up and down until it becomes hard.

  4. INSTALL DIESEL THROTTLE BODY ASSEMBLY

  5. INSTALL PUMP DRIVE SHAFT PULLEY

  6. INSTALL TIMING BELT NO.1 COVER

  7. INSTALL ENGINE WIRE

  8. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Install the front door scuff.

    2. Install the floor mat.

    3. Install the engine service hole sub-cover with the 7 bolts.

  9. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  10. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  11. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Install the clip and nut, and then connect the shift cable to the transmission.

  12. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Install the clip and nut, and then connect the select cable to the transmission.

  13. INSTALL FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)

    Click here

  14. INSTALL FRONT SEAT ASSEMBLY RH (W/O TILT CAB CAB TYPE)

    Click here

  15. INSTALL BATTERY NEGATIVE TERMINAL

  16. INSPECT FUEL LEAK

    CAUTION:


    • During ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud, so pay attention.

    • During ACTIVE TEST mode, fuel becomes high pressure, so take much care not to expose your eyes, hands, or body to the fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine stops.

      If there is fuel leakage, replace those parts.

    2. While cranking or starting the engine, check that there are no leaks from any part of the fuel system.

      If there is fuel leakage, replace those parts.

    3. Disconnect the return hose from the common rail.

    4. While cranking the engine, check fuel leakage from the return pipe.

      If there is fuel leakage, replace the common rail assembly Click here.

    5. A01KFQVE01
      Text in Illustration
      *1 Intelligent Tester

      Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the FUEL LEAK test of ACTIVE TEST mode on the intelligent tester.

    8. If you have no intelligent tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable.

      If there is fuel leakage, replace those parts.

    10. Reconnect the return hose to the common rail.