FUEL SUPPLY PUMP INSTALLATION

CAUTION / NOTICE / HINT

Note

After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE

INSTALL FUEL SUPPLY PUMP ASSEMBLY
Note

Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.
1. Check that the injection gear in the timing gear case assembly moves back and forth smoothly.
2. Install a new O-ring to the fuel supply pump assembly.
3. Apply a light coat of engine oil to the O-ring.
4. *a Groove
  
  *b Set Key
  
  Align the groove of the injection gear with the set key on the fuel supply pump drive shaft.
5. Install the fuel supply pump assembly with the 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Set a new O-ring before tightening the set nut.
7. Using SST, hold the crankshaft pulley and install the set nut.
  
  SST
  
  09213-58014 ( 91551-80840 )
  
  09330-00021
  
  Torque:
  
  63.7 N*m { 650 kgf*cm, 47 ft.*lbf }
8. Install the pump drive shaft pulley and No. 2 camshaft timing pulley flange with the 4 bolts.
  
  Torque:
  
  31 N*m { 316 kgf*cm, 23 ft.*lbf }
9. Move the pump drive shaft pulley back and forth to check the thrust clearance of the fuel supply pump drive shaft.
  
  Standard thrust clearance (reference)
  
  0.15 to 0.55 mm (0.00590 to 0.0217 in.)
  
  If there is no clearance, disassemble and reassemble the fuel supply pump assembly and pump drive shaft pulley. Then repeat the step above.
10. Connect the connector to the fuel temperature sensor.
11. Connect the connector to the suction control valve.
12. Connect the fuel hose and No. 1 fuel hose to the fuel supply pump assembly, and slide the 2 clamps to secure the hoses.
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
1. Temporarily install the fuel inlet pipe sub-assembly with the union nuts.
  Note
  - When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
  - Keep the fuel inlet pipe sub-assembly free of foreign matter.
2. *a Torque Wrench Fulcrum Length
  
  Using a 17 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the common rail assembly side.
  
  Torque:
  
  Specified tightening torque
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
    
    Click here
  - When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
3. *a Torque Wrench Fulcrum Length
  
  Using a 17 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply pump assembly side.
  
  Torque:
  
  Specified tightening torque
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
    
    Click here
  - When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Click here
INSTALL TIMING BELT

Click here
INSTALL RADIATOR ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Click here
ADD ENGINE COOLANT

Click here
BLEED AIR FROM FUEL SYSTEM

Click here
PERFORM FUEL SUPPLY PUMP INITIALIZATION

Click here
INSPECT FOR COOLANT LEAK

Click here
INSPECT FOR FUEL LEAK

Click here

*a	Groove
*b	Set Key