ТОПЛИВНЫЙ БАК УСТАНОВКА

УСТАНОВИТЕ ПРОДУВОЧНЫЙ ПАТРУБОК ТОПЛИВНОГО БАКА В СБОРЕ

1. 

   Apply a light coat of diesel fuel to a new gasket and install the gasket to the fuel tank.

   Table 6. Text in Illustration

   *1	New Gasket

2. Install the fuel tank vent tube to the fuel tank.

   Note:

   Make sure that the fuel sender gauge arm does not bend.

3. 

   Align the protrusions of the fuel tank vent tube with the notches of the fuel tank.

   Table 7. Text in Illustration

   *1	Notch
   *2	Protrusion

УСТАНОВИТЕ КРЕПЕЖНУЮ ДЕТАЛЬ ДАТЧИКА ТОПЛИВНОГО НАСОСА

1. 

   While holding the fuel suction with pump and gauge tube by hand to prevent it from tilting, align the start marks on a new fuel pump gauge retainer and fuel tank and tighten the fuel pump gauge retainer 180° by hand.

   Table 8. Text in Illustration

   *1	Start Mark (Fuel Tank Side)
   *2	Start Mark (Fuel Pump Gauge Retainer Side)
   	Front Side of Vehicle

   Tip:

   Check that there is no damage, dents, foreign matter, or other defects on the threads of the fuel tank.

2. 

   Temporarily install SST (plate and 2 claws) to the fuel pump gauge retainer.

   09808-14030

   Table 9. Text in Illustration

   *1	SST (Plate)
   *2	SST (Claw)

   Tip:
   

   • Be sure to use 2 SST (claws) as shown in the illustration.

   • Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

3. While securely pressing SST (claws) against the fuel pump gauge retainer ribs, install the 2 bolts.

   Tip:

   Install SST while pressing SST (claws) against the fuel pump gauge retainer (towards the center of SST).

4. Install SST (handle).

5. 

   Tighten the fuel pump gauge retainer approximately 270° so that the start mark on the fuel pump gauge retainer is in the position shown in the illustration.

   09808-14030

   Table 10. Text in Illustration

   *1	Start Mark (Fuel Pump Gauge Retainer Side)
   	Turn
   	Front Side of Vehicle

   Note:
   

   • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or fuel tank may result.

   • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

   • Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.

   • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

   • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

   Tip:
   

   • Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to tighten the fuel pump gauge retainer.

   • The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.

ПОДСОЕДИНИТЕ ВОЗВРАТНУЮ ТРУБКУ ТОПЛИВНОГО БАКА

1. 

   Push the fuel tube joint into the plug of the fuel tank vent tube, and then install the tube joint clip.

   Note:
   

   • Check that there are no scratches or foreign objects on the connecting parts.

   • Check that the fuel tube joint is inserted securely.

   • Check that the tube joint clip is on the collar of the fuel tube joint.

   • After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

   Table 11. Text in Illustration

   *1	Tube Joint Clip
   *2	Fuel Tube Joint
   *3	O-Ring
   *4	Tube Joint Clip
   *5	Collar
   *a	CORRECT
   *b	INCORRECT

ПОДСОЕДИНИТЕ ПОДАЮЩИЙ ТОПЛИВОПРОВОД В СБОРЕ

1. 

   Push the fuel tube joint into the plug of the fuel tank vent tube, and then install the tube joint clip.

   Note:
   

   • Check that there are no scratches or foreign objects on the connecting parts.

   • Check that the fuel tube joint is inserted securely.

   • Check that the tube joint clip is on the collar of the fuel tube joint.

   • After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

   Table 12. Text in Illustration

   *1	Tube Joint Clip
   *2	Fuel Tube Joint
   *3	O-Ring
   *4	Tube Joint Clip
   *5	Collar
   *a	CORRECT
   *b	INCORRECT

УСТАНОВИТЕ КРЫШКУ ТЕХНОЛОГИЧЕСКОГО ОТВЕРСТИЯ ЗАДНЕГО ПОЛА

1. 

   Connect the sender gauge connector.

2. Install the rear floor service hole cover with new butyl tape.

   Note:

   Be careful that the rear floor service hole cover does not overlap the protrusions of the floor panel when installing.

УДАЛИТЕ ВОЗДУХ ИЗ ТОПЛИВНОЙ СИСТЕМЫ

1. 

   Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

   Note:
   

   • Hand pump pumping speed: Max. 2 strokes/ sec.

   • The hand pump must be pushed with a full stroke during pumping.

   • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

   • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

   • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

   • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

2. Start the engine.

   Note:
   

   • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

   • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

   • Use a fully-charged battery.

   
   

   1. When the engine can be started, proceed to the next step.

   2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

3. Turn the ignition switch off.

4. Connect the intelligent tester to the DLC3.

5. Turn the ignition switch to ON and turn the intelligent tester on.

6. Clear the DTCs.

   
   

   • for DPF: (Click here)

   • for CCo: (Click here)

7. Start the engine.*1

8. 

   Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

10. 

    Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

    Tip:

    When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

11. Enter the following menus: Powertrain / Engine and ECT / DTC.

12. Read Current DTCs.

    
    

    1. When no DTCs are output, the air bleeding is completed.

    2. If any DTCs are output, proceed to the next step.

13. Clear the DTCs.

    
    

    • for DPF: (Click here)

    • for CCo: (Click here)

14. Repeat steps *1 to *3.

15. Enter the following menus: Powertrain / Engine and ECT / DTC.

16. Read Current DTCs.

    OK
    No DTCs are output.

ПРОВЕРЬТЕ, НЕТ ЛИ УТЕЧЕК ТОПЛИВА

1. Perform Active Test.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch to ON.

   3. Start the engine.

   4. Turn the intelligent tester on.

   5. Enter the following menus: Powertrain / Engine / Active Test.

   6. Perform the Active Test.

      Tester Display	Test Part	Control Range	Diagnostic Notes
      Test the Fuel Leak	Pressurizes common rail internal fuel pressure, and checks for fuel leaks	Stop/Start	Performs inspection of the high pressure fuel system. Engine Speed: 2050 rpm Fuel Pressure: 172000 kPa Target Common Rail Pressure: 176000 kPa Target Pump SCV Current: 1400 mA MAP: 176 kPa MAF: 39 g/sec.

ПРОВЕРЬТЕ, НЕТ ЛИ УТЕЧЕК ОТРАБОТАВШИХ ГАЗОВ

1. 

   Убедитесь в отсутствии утечек отработавших газов в местах (зонах соединений выпускных труб и зонах установки всех датчиков), показанных на рисунке.