FUEL SUPPLY PUMP INSTALLATION

INSTALL FUEL SUPPLY PUMP ASSEMBLY
1. Install the supply pump assembly with the 3 bolts.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
2. Align the projection on the drive shaft with the groove of the supply pump gear.
3. Using SST, install the supply pump gear with the nut.
  
  SST
  
  09960-10010 ( 09962-01000 )
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
4. Install the bracket with the 2 bolts and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
5. Push the 2 tube connectors into the 2 pipes until the tube connectors make a "click" sound.
  Note
  
  Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
  
  After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
6. Connect the connector.
7. Temporarily install a new injection pipe.
  Note
  - Keep the joints of the injection pipes clean.
  - Screw on by hand, to the end of the thread, the unions of the injection pipes on the supply pump side and on the common rail side.
8. Using SST, tighten the injection pipe with the union nuts.
  
  SST
  
  09023-38401
  
  Torque:
  
  When using SST
  
  17 N*m { 173 kgf*cm, 13 ft.*lbf }
  
  When not using SST
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 300 mm (11.81 in.) (supply pump end).
  
  Use a torque wrench with a fulcrum length of 345 mm (13.58 in.) (common rail end).
9. Using SST, retighten the injection pipe with the union nuts.
  
  SST
  
  09023-38401
  
  Torque:
  
  When using SST
  
  23 N*m { 232 kgf*cm, 17 ft.*lbf }
  
  When not using SST
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  Tech Tips
  - Use a torque wrench with a fulcrum length of 300 mm (11.81 in.) (supply pump end).
  - Use a torque wrench with a fulcrum length of 345 mm (13.58 in.) (common rail end).
SET TIMING MARK
1. Using SST, set the pulley of the camshaft so that the timing holes of the camshaft drive pulley and the cylinder head are aligned.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
2. Using the crankshaft pulley bolt, turn the crankshaft so that the timing holes of the crankshaft timing pulley and the oil pump are aligned.
INSTALL TIMING BELT
1. Temporarily install the timing belt tensioner with the bolt.
2. Install the timing belt.
3. Check that the timing holes are aligned as shown in the illustration.
4. Using a hexagon socket wrench, turn the timing belt tensioner as shown in the illustration.
  
  Tech Tips
  
  Part A should be positioned within area B.
5. Tighten the timing belt tensioner bolt.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
CHECK VALVE TIMING
1. Slowly turn the crankshaft 2 complete revolutions (720°).
2. Check that the timing holes are aligned as shown in the illustration.
3. Remove the crankshaft pulley bolt.
INSTALL CRANK POSITION SENSOR
1. Install the crankshaft timing pulley support with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Install the crankshaft position sensor with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Connect the crankshaft position sensor connector.
INSTALL ENGINE MOUNT BRACKET
1. Install the engine mount bracket with the 4 bolts.
  
  Torque:
  
  55 N*m { 561 kgf*cm, 41 ft.*lbf }
INSTALL TIMING BELT LOWER COVER
1. Install the timing belt lower cover with the 5 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL CRANKSHAFT PULLEY
1. Temporarily install the timing belt tensioner with the bolt.
2. Using SST, hold the crankshaft pulley.
  
  SST
  
  09330-00021
3. Tighten the bolt.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
4. Mark the top surface of the crankshaft pulley bolt with paint.
5. Retighten the bolt by an additional 190 degrees as shown in the illustration.
INSTALL V-RIBBED BELT TENSIONER SUB-ASSEMBLY
1. Install the V-ribbed belt tensioner sub-assembly with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install 4 new O-rings and a gasket to the cylinder head cover.
2. Temporarily install the cylinder head cover with the 10 bolts.
3. Tighten the 10 bolts in the order shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Connect the diesel throttle valve connector.
INSTALL EGR VALVE ASSEMBLY
1. Install a new O-ring to the EGR pipe.
2. Temporarily install the EGR valve assembly and gasket with the 2 screws and 2 bolts.
3. Install the clamp with the bolt.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
4. Tighten the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
5. Using a "torx" socket wrench, tighten the 2 screws.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL EGR COOLER WATER BY-PASS HOSE
1. Using pliers, slide the 2 clips to install the water by-pass hose.
INSTALL HEATER WATER OUTLET HOSE A
1. Using pliers, slide the clip to install the heater water outlet hose A.
CONNECT ENGINE WIRE NO.2
1. Install the engine wire No.2 to the injector.
  
  CAUTION:
  
  Be sure to connect the injector connectors correctly to prevent malfunctions in the injector.
2. Connect the fuel pressure sensor connector.
3. Connect the glow harness connector.
INSTALL FUEL FILTER ASSEMBLY
1. Temporarily install the fuel filter assembly with the 2 bolts and screw.
2. Tighten the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Using a "torx" socket wrench, tighten the screw.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
4. Connect the fuel heater connector.
5. Connect the fuel level warning switch connector.
6. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel return hose to the fuel pump return pipe.
7. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel hose to the fuel pump pipe.
8. Connect the pressure control valve connector.
9. Connect the fuel return hose to the No.4 injector.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
1. Temporarily install the air cleaner case, air hose No.1 clamp and 2 screws.
2. Using a "torx" socket wrench, tighten the 2 screws.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Tighten the air hose No.1 clamp.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
4. Connect the PCV hose.
INSTALL TURBO PRESSURE SENSOR
1. Install the turbo pressure sensor with the bolt.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Connect the turbo pressure sensor connector.
3. Connect the turbo pressure sensor to the cylinder head cover.
INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
1. Install a new O-ring to the intake air resonator.
2. Temporarily install the intake air resonator with the clamp, bolt and screw.
3. Tighten the bolt.
  
  Torque:
  
  7.5 N*m { 77 kgf*cm, 66 in.*lbf }
4. Tighten the air hose No.1 clamp.
  
  Torque:
  
  3.5 N*m { 36 kgf*cm, 31 in.*lbf }
5. Using a "torx" socket wrench, tighten the screw.
  
  Torque:
  
  7.5 N*m { 77 kgf*cm, 66 in.*lbf }
6. Connect the air temperature sensor connector.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air filter element.
2. Using a "torx" socket wrench, install the air cleaner case sub-assembly with the 3 screws.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL TIMING BELT UPPER COVER
1. Install the timing belt upper cover with the 5 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL ENGINE W/ TRANSAXLE

Click here