FUEL SUPPLY PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note


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

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

Tech Tips

After replacing the supply pump assembly, perform the "SUPPLY PUMP INITIALIZATION PROCEDURE" function using the GTS.

Click here

PROCEDURE


  1. INSTALL SUPPLY PUMP ASSEMBLY


    1. A012MWT

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

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

    3. A012J5T

      Install the supply pump drive coupling.

      Note

      When reusing the coupling, install 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 assembly with the 2 bolts.

      Torque:
      20.5 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 assembly connector.

    6. Connect the fuel temperature sensor connector.

  2. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. A012LRGC03
      *1 Check Valve
      *a Union Bolt

      Temporarily install the fuel tube sub-assembly with 2 new gaskets, the check valve and union bolt.

    2. Tighten the check valve.

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

    3. Tighten the union bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    4. A012KRL

      Insert the fuel tube connector into the exhaust fuel addition injector assembly.

    5. A012N16C03
      *1 Exhaust Fuel Addition Injector Assembly
      *a Fuel Tube Connector
      *b Retainer
      *c O-ring

      Turn the retainer as shown in the illustration until it makes a "click" sound.

      Note


      • If the fuel tube connector is not connected to the exhaust fuel addition injector assembly in the correct position, the retainer cannot be turned further in the direction indicated by the arrow.

      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tube connector and exhaust fuel addition injector assembly before performing this work.

      • After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

    6. Connect the exhaust fuel addition injector assembly connector.

  3. INSTALL FUEL HOSE PROTECTOR

    Click here

  4. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. A012LGM

      Temporarily install the fuel inlet pipe sub-assembly with the 2 clamps and nut.

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

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

      Click here

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

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

      Click here

    4. Tighten the injection pipe clamp nut.

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

  5. INSTALL NO. 1 FUEL HOSE


    1. A012HNHC01
      *a 1 to 5 mm

      Connect the No. 1 fuel hose, then slide the 2 clips to secure it.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the tabs of the clip with the alignment mark of the hose and connect the hose.

      • Position the clip so that the distance is 1 to 5 mm (0.0394 to 0.197 in.).

  6. INSTALL NO. 3 FUEL HOSE


    1. A012JNXC01
      *a 2 to 3 mm
      *b 2 to 6 mm

      Install the No. 3 fuel hose, then fit it with the 2 clips as shown in the illustration.

      Tech Tips


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

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

  7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  8. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  10. PERFORM INITIALIZATION


    1. Perform supply pump assembly initialization procedure.

      Click here

  11. BLEED AIR FROM FUEL SYSTEM

    Click here

  12. INSPECT FOR FUEL LEAK

    Click here

  13. INSTALL NO. 1 ENGINE COVER

    Click here