FUEL SUPPLY PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL FUEL SUPPLY PUMP ASSEMBLY


    1. A004MRK

      Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the supply pump.

    3. A004NDN

      Install the supply pump drive coupling.

      Note

      When reusing the coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed.

      Tech Tips

      Line up the coupling with the groove in the camshaft end.

    4. Install the supply pump with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Line up the end of the supply pump drive shaft with the supply pump drive coupling.

    5. Connect the suction control valve connector.

    6. Connect the fuel temperature sensor connector.

  2. INSTALL NO. 2 FUEL PIPE (for CCo)


    1. Temporarily install the No. 2 fuel pipe and 2 new gaskets with the check valve and union bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the union bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  3. INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. Temporarily install the fuel tube and 2 new gaskets with the check valve and union bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the union bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    4. A004PU1

      Connect the fuel tube connector to the injector.

    5. A004O9OE10
      Text in Illustration
      *1 Fuel Tube Connector
      *2 Injector
      *3 Retainer
      *4 O-Ring

      Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

      Note

      If the fuel tube connector is not inserted to the correct position on the injector, the retainer cannot be turned far enough in the direction of the arrow.

    6. Connect the exhaust fuel addition injector connector.

  4. INSTALL FUEL HOSE PROTECTOR (for DPF)

    Click here

  5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe with the 2 clamps and nut.

    2. Using a 14 mm union nut wrench, first tighten the nut at the common rail end of the fuel inlet pipe.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Using a 14 mm union nut wrench, tighten the nut at the supply pump end of the fuel inlet pipe.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Tighten the No. 2 injection pipe clamp nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  6. INSTALL NO. 1 FUEL HOSE


    1. A004OIVE03
      Text in Illustration
      *1 Alignment Mark
      *a 1 to 5 mm (0.0394 to 0.197 in.)

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 1 fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the claws of the clamp with the hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the hose is 1 to 5 mm (0.0394 to 0.197 in.).

  7. INSTALL NO. 3 FUEL HOSE


    1. A004RD6E01
      Text in Illustration
      *a 2 to 3 mm (0.0787 to 0.118 in.)
      *b 2 to 6 mm (0.0787 to 0.236 in.)

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 3 fuel hose.

      Tech Tips


      • Push on the fuel hose so that the clearance is 2 to 3 mm (0.0787 to 0.118 in.).

      • Position the clamp so that the distance from the end of the hose is 2 to 6 mm (0.0787 to 0.236 in.).

  8. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  9. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  10. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  12. PERFORM INITIALIZATION


  13. BLEED AIR FROM FUEL SYSTEM

    Click here

  14. INSPECT FOR FUEL LEAK

    Click here

  15. INSTALL NO. 1 ENGINE COVER

    Click here