SUCTION CONTROL VALVE INSTALLATION

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. INSTALL SUCTION CONTROL VALVE ASSEMBLY

    Note


    • Before replacing the suction control valve, be sure to clean the surrounding area.

    • When replacing the suction control valve, make sure that your hands are clean and do not use gloves, etc.


    1. Apply engine oil to a new O-ring.

      Note

      Be sure to use clean engine oil.

    2. A00KTNJ

      Install the O-ring to the O-ring groove of the fuel supply pump.

      Note

      Make sure that the O-ring and O-ring groove are free of foreign matter and are not damaged.

    3. A00KT4NE01
      Text in Illustration
      *1 Guide Pin

      Install guide pins used for the insertion of the suction control valve to the bolt holes.

      Tech Tips


      • When installing the guide pins, it is sufficient to fix them lightly in place by hand.

      • The guide pins are used to make sure that the suction control valve remains perpendicular to the fuel supply pump when it is inserted.

    4. A00KT18

      Apply engine oil to the O-ring at the end of the suction control valve.

      Note

      Be sure to use clean engine oil.

    5. A00KXF9E03
      Text in Illustration
      *1 Guide Pin
      *2 Fuel Supply Pump

      While making sure that the suction control valve and fuel supply pump remain perpendicular to each other, slide the suction control valve along the guide pins and insert it into the fuel supply pump as shown in the illustration.

      Note


      • Make sure that the contact surfaces of the fuel supply pump and suction control valve are free of foreign matter and are not damaged.

      • Do not insert the suction control valve at an angle.

      • Make sure that the O-ring does not get pinched between the parts. If it does, replace it with a new one.

      • Insert the suction control valve until it contacts the fuel supply pump.

    6. While holding the suction control valve in place, remove the guide pins, temporarily install 2 new bolts and uniformly tighten them by hand.

      Note

      Do not use tools. Tighten the bolts by hand until the surfaces of the suction control valve and fuel supply pump contact each other.

    7. Using a 5 mm hexagon wrench, uniformly tighten the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    8. Connect the connector to the suction control valve.

      Note

      Make sure that there is not excessive slack or tension in the wire harness of the suction control valve.

  2. INSTALL FUEL SUPPLY PUMP ASSEMBLY


  3. ADD ENGINE COOLANT


  4. BLEED AIR FROM FUEL SYSTEM


  5. PERFORM FUEL SUPPLY PUMP INITIALIZATION


  6. INSPECT FOR COOLANT LEAK

    Note

    Before each inspection, turn the A/C switch off.

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

  7. INSPECT FOR FUEL LEAK