SUCTION CONTROL VALVE INSTALLATION


  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. A00OT5Z

      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. A00OSJ6E01
      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. A00OQSH

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

      Note

      Be sure to use clean engine oil.

    5. A00ORJ1E01
      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 AIR CLEANER CASE SUB-ASSEMBLY


    1. A00OUZE

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  3. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  4. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Connect the air cleaner hose.

    2. A00OVRGE01

      Attach the 4 clamps to install the air cleaner cap.

    3. Connect the No. 2 ventilation hose.

    4. Attach the clamp and connect the mass air flow meter connector.

  5. BLEED AIR FROM FUEL SYSTEM


    1. A010OM8

      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. A010PR6E03

      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.

      A010QBAE04

      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.

  6. PERFORM INITIALIZATION


    1. Perform the supply pump initialization procedure Click here.

  7. 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.

  8. INSTALL NO. 1 ENGINE COVER


    1. A003DQW

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