НАГНЕТАЮЩИЙ ТОПЛИВНЫЙ НАСОС УСТАНОВКА

Note


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

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


  1. INSTALL FUEL SUPPLY PUMP ASSEMBLY


    1. A01ITMV

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

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

    3. A01IN19

      Install the supply pump drive coupling.

      Note

      When reusing the coupling, it must be installed 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 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 supply pump drive coupling.

    5. Connect the suction control valve connector.

    6. Connect the fuel temperature sensor connector.

  2. INSTALL FUEL TUBE SUB-ASSEMBLY


    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. A01IPE8

      Connect the fuel tube connector to the exhaust fuel addition injector assembly.

    5. A01IQ7XE01
      Text in Illustration
      *1 Fuel Tube Connector
      *2 Exhaust Fuel Addition Injector Assembly
      *3 Retainer
      *4 O-Ring

      Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

      Note

      If the fuel tube connector is not inserted to the correct position on the exhaust fuel addition injector assembly, the retainer cannot be turned far enough in the direction of the arrow.

    6. Connect the exhaust fuel addition injector connector.

  3. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector with the bolt.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }
  4. 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. Using a 14 mm union nut wrench, first 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 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 nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

      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 }
  5. INSTALL NO. 1 FUEL HOSE


    1. A01IPAIE02
      Text in Illustration
      *1 Alignment Mark
      *2 1 to 5 mm (0.0394 to 0.197 in.)

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 1 fuel hose to the fuel supply pump assembly and fuel filter assembly.

      Tech Tips


      • Align the alignment marks and connect the No. 1 fuel hose.

      • Align the claws of the clamp with the No. 1 fuel hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the No. 1 fuel hose is 1 to 5 mm (0.0394 to 0.197 in.).

  6. INSTALL NO. 3 FUEL HOSE


    1. A01IP1SE01
      Text in Illustration
      *a 2 to 3 mm (0.0787 to 0.118 in.)
      *b 2 to 6 mm (0.0787 to 0.236 in.)

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 3 fuel hose to the No. 2 nozzle leakage pipe and fuel supply pump assembly.

      Tech Tips


      • Push on the No. 3 fuel hose so that the clearance is 2 to 3 mm (0.0787 to 0.118 in.).

      • Position the clamp so that the distance from the end of the No. 3 fuel hose is 2 to 6 mm (0.0787 to 0.236 in.).

  7. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Установите корпус воздушного фильтра и закрепите его 3 болтами.

      Torque:
      7,0 Н*м  { 71 кгс*см, 62 фунт-сила-дюйма }
  8. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  9. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01INV0E02
      Обозначения на рисунке
      *a Верх

      Подсоедините шланг воздушного фильтра к турбонагнетателю и надвиньте хомут, чтобы закрепить его.

      Tech Tips

      Ориентация шлангового зажима показана на рисунке.

    2. Присоедините 4 зажима, чтобы закрепить крышку воздушного фильтра.

    3. Подсоедините шланг системы принудительной вентиляции картера к головке блока цилиндров и надвиньте хомут, чтобы закрепить его.

    4. Подсоедините разъем датчика массового расхода воздуха и закрепите зажимом.

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  11. PERFORM INITIALIZATION

    Click here

  12. BLEED AIR FROM FUEL SYSTEM


    1. A01IQ0Q

      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 Click here.

    7. Start the engine.*1

    8. A01IRMJE03

      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.

      A01IRYOE04

      Tech Tips

      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 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.
  13. INSPECT FOR FUEL LEAK

    Tech Tips

    Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.


    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: 1.4 A

        • MAP: 176 kPa

        • MAF: 39 g/sec.

  14. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.