FUEL SUPPLY PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note

When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

Replaced Parts (A)	Pipes Requiring New Replacement
Injector assembly (including shuffling the injector assemblies between the cylinders) Common rail assembly Cylinder head sub-assembly	No. 1 injection pipe sub-assembly No. 2 injection pipe sub-assembly
Supply pump assembly Common rail assembly Cylinder block sub-assembly Cylinder head sub-assembly Cylinder head gasket Timing chain case assembly	No. 1 injection pipe sub-assembly No. 2 injection pipe sub-assembly Fuel inlet pipe sub-assembly

After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.
The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.
Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.
Make sure foreign matter does not enter the fuel path.

PROCEDURE

INSTALL SUPPLY PUMP ASSEMBLY
Note
- Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.
- With SST set, do not turn the crankshaft more than a half rotation.
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the supply pump assembly.
3. *a Groove
  
  To insert the supply pump assembly shaft in the supply pump shaft sprocket, it may be necessary to turn the supply pump assembly several degrees and the groove in the supply pump assembly shaft are aligned.
4. *a Hold
  
  Turn
  
  Using SST, tighten clockwise the supply pump assembly, and then temporarily install the 3 fuel supply pump fixing nuts.
  
  SST
  
  09213-58014 ( 91551-80840 )
  
  09330-00021
  
  09241-11010
5. Using SST, tighten and insert the supply pump assembly up to the position shown in the illustration and tighten the 3 fuel supply pump fixing nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Tech Tips
  
  After tightening the part with SST, a gap of 2 to 3 mm in area A shown in the illustration is normal.
6. Remove SST and the 3 set bolts.
7. *a Hold
  
  Turn
  
  Using SST, hold the crankshaft pulley sub-assembly and tighten the set nut.
  
  Torque:
  
  137 N*m { 1397 kgf*cm, 101 ft.*lbf }
INSTALL TIMING CHAIN COVER PLATE
1. Install the timing chain cover plate and new gasket with the 3 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Note
  
  Do not install the timing chain cover plate with the bolts included with SST.
INSTALL FUEL PUMP MOTOR WIRE
1. Attach the clamp and install the fuel pump motor wire.
2. Connect the fuel pump motor wire connector.
INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY
1. Install the fuel injection pump cover sub-assembly to the supply pump assembly.
INSTALL NO. 2 FUEL HOSE
1. Install the No. 2 fuel hose to the supply pump assembly and No. 3 nozzle leakage pipe assembly, and slide the 2 clamps to secure it.
INSTALL NO. 1 FUEL HOSE
1. Install the No. 1 fuel hose to the supply pump assembly and No. 2 fuel pipe, and slide the 2 clamps to secure it.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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INSTALL FAN SHROUD

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INSTALL RADIATOR RESERVOIR

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INSTALL NO. 1 OIL RESERVOIR BRACKET

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CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

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INSTALL NO. 1 RADIATOR HOSE

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INSTALL NO. 2 AIR TUBE

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INSTALL NO. 4 AIR HOSE

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INSTALL INTAKE MANIFOLD

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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

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BLEED AIR FROM FUEL SYSTEM

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INSPECT FOR FUEL LEAK

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INSTALL NO. 1 ENGINE UNDER COVER

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*a	Hold
	Turn

*a	Hold
	Turn