FUEL SUPPLY PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note


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

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

PROCEDURE


  1. INSTALL FUEL SUPPLY PUMP ASSEMBLY


    1. A01V79V

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

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

    3. A01VB19

      Install the No. 1 supply pump drive coupling.

      Note

      When reusing the No. 1 supply pump drive coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed.

      Tech Tips

      Line up the No. 1 supply pump drive coupling with the groove in the camshaft end.

    4. Install the fuel supply pump assembly 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 No. 1 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 sub-assembly 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. Connect the fuel tube sub-assembly.

      Click here

    5. 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 sub-assembly with the 2 No. 2 injection pipe clamps and nut.

    2. A01V8F3C01
      *a Fuel Supply Pump Assembly Side
      *b Common Rail Assembly Side

      Using a 14 mm union nut wrench, tighten the 2 fuel inlet pipe sub-assembly union nuts on the fuel supply pump assembly side.

      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 2 fuel inlet pipe sub-assembly union nuts on the common rail assembly side.

      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. CONNECT NO. 1 FUEL HOSE


    1. Connect the No. 1 fuel hose to the fuel supply pump assembly, and slide the 2 clamps to secure it.

  7. INSTALL NO. 3 FUEL HOSE


    1. Install the No. 3 fuel hose to the No. 2 nozzle leakage pipe assembly and fuel supply pump assembly, and slide the 2 clamps to secure it.

  8. INSTALL AIR CLEANER CASE

    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