SUCTION CONTROL VALVE INSTALLATION


  1. INSTALL SUCTION CONTROL VALVE ASSEMBLY

    Note


    • Before replacing the suction control valve, be sure to clean the surrounding area.

    • When replacing the suction control valve, make sure that your hands are clean and do not use gloves, etc.

    • Be careful as the installation procedure differs depending on the type of suction control valve.

    Tech Tips

    There are different types of suction control valve assemblies as shown in the illustration. Therefore, be sure to refer to the replacement table below when replacing the suction control valve assembly.

    A01KF0IE05
    Text in Illustration
    *A SV1 Type *B SV2 Type
    *C SV1 Type with Attachment - -
    *1 Attachment *2 Injection Pump
    *3 Suction Control Valve - -
    *a 45 mm (1.77 in.) *b 23 mm (0.906 in.)
    Suction Control Valve Assembly Replacement Table
    Suction Control Valve Assembly Currently Installed on Vehicle Replacement Part to Use
    SV1 Type SV1 Type
    SV2 Type SV1 Type with Attachment
    SV1 Type with Attachment SV1 Type with Attachment

    1. Apply engine oil to a new O-ring.

      Note


      • Be sure to use clean engine oil.

      • As the type of O-ring differs depending on the type of suction control valve, be sure to check the following table before installation.

        table before installation.
        Type of Suction Control Valve Assembly O-ring Inner Diameter
        SV1 Type 22.8 mm (0.898 in.)
        SV1 Type with Attachment 19.8 mm (0.780 in.)
    2. A01KHLP

      Install the O-ring to the O-ring groove of the injection pump.

      Note

      Make sure that the O-ring and O-ring groove are free of foreign matter and are not damaged.

    3. A01KGPUE01
      Text in Illustration
      *1 Guide Pin

      Install guide pins used for the insertion of the suction control valve to the bolt holes.

      Tech Tips


      • When installing the guide pins, it is sufficient to fix them lightly in place by hand.

      • The guide pins are used to make sure that the suction control valve remains perpendicular to the injection pump when it is inserted.

    4. A01KHL5E01
      Text in Illustration
      *A SV1 Type
      *B SV1 with Attachment

      Apply engine oil to the O-ring at the end of the suction control valve.

    5. A01KFA4E01
      Text in Illustration
      *A SV1 Type
      *1 Guide Pin
      *2 Injection Pump

      SV1 Type:


      1. While making sure that the suction control valve and injection pump remain perpendicular to each other, slide the suction control valve along the guide pins and insert it into the injection pump as shown in the illustration.

        Note


        • Make sure that the contact surfaces of the injection pump and suction control valve are free of foreign matter and are not damaged.

        • Do not insert the suction control valve at an angle.

        • Make sure that the O-ring does not get pinched between the parts. If it does, replace it with a new one.

        • Insert the suction control valve until it contacts the injection pump.

      2. While holding the suction control valve in place, remove the guide pins, temporarily install 2 new bolts and uniformly tighten them by hand.

        Note

        Do not use tools. Tighten the bolts by hand until the surfaces of the suction control valve and injection pump contact each other.

      3. Using a 5 mm hexagon wrench, uniformly tighten the 2 bolts.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 ft.*lbf }

      4. Connect the connector to the suction control valve.

        Note

        Make sure that there is not excessive slack or tension in the wire harness of the suction control valve.

    6. SV1 Type with Attachment:


      1. Apply engine oil to a new O-ring.

        Note

        Be sure to use clean engine oil.

        Tech Tips

        The inner diameter of the O-ring is 22.8 mm (0.898 in.).

        Install the O-ring to the deep O-ring groove on the attachment, and then temporarily install the attachment to the suction control valve.

      2. A01KF5OE04
        Text in Illustration
        *1 Attachment
        *2 New O-ring
        *3

        Suction Control Valve

        (SV1 Type with Attachment)
        *a Injection Pump Side
        *b Suction Control Valve Side
        *c O-ring Groove (Shallow)
        *d O-ring Groove (Deep)

        Install the O-ring to the deep O-ring groove on the attachment, and then temporarily install the attachment to the suction control valve.

        Note


        • When installing the attachment, make sure that the deep O-ring groove is facing the suction control valve.

        • Make sure that the O-ring and O-ring groove are free of foreign matter and are not damaged.

        • Make sure that the contact surfaces of the suction control valve and attachment are free of foreign matter and are not damaged.

      3. A01KET4E01
        Text in Illustration
        *A SV1 Type with Attachment
        *1 Guide Pin
        *2 Attachment
        *3 Injection Pump

        While making sure that the suction control valve and injection pump remain perpendicular to each other, slide the suction control valve and attachment together as a set along the guide pins and insert the suction control valve into the injection pump as shown in the illustration.

        Note


        • Make sure that the contact surfaces of the injection pump and suction control valve are free of foreign matter and are not damaged.

        • Do not insert the suction control valve at an angle.

        • Make sure that the O-ring does not get pinched between the parts. If it does, replace it with a new one.

        • Insert the suction control valve until it contacts the injection pump.

      4. While holding the suction control valve in place, remove the guide pins, temporarily install 2 new bolts and uniformly tighten them by hand.

        Note

        Do not use tools. Tighten the bolts by hand until the surfaces of the suction control valve and attachment, and the surfaces of the attachment and injection pump contact each other.

      5. Using a 5 mm hexagon wrench, uniformly tighten the 2 bolts.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 ft.*lbf }

      6. Connect the connector to the suction control valve.

        Note

        Make sure that there is not excessive slack or tension in the wire harness of the suction control valve.

  2. INSTALL INJECTION PUMP ASSEMBLY

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