FUEL SUPPLY PUMP INSTALLATION


  1. INSTALL SUPPLY PUMP DRIVE COUPLING


    1. A011909E03
      Text in Illustration
      *1 Camshaft
      *2 Supply Pump Drive Coupling
      *a Correct
      *b Incorrect

      Install the supply pump drive coupling into the camshaft.

      Note

      Install the supply pump drive coupling in the correct direction.

  2. INSTALL SUPPLY PUMP ASSEMBLY

    Note

    When installing, clean the seal surfaces of the fuel inlet pipe, supply pump and common rail.


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

    2. Install the O-ring onto the supply pump.

    3. Temporarily install the supply pump with the 3 bolts.

    4. Remove the plastic bag and rubber band from the supply pump.

  3. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the supply pump, the fuel inlet pipe must also be replaced.

    • Replace the fuel inlet pipe with a new one when the fuel inlet pipe has been removed and reinstalled more than 5 times.


    1. A011ADSE02
      Text in Illustration
      *a Correct
      *b Incorrect

      Temporarily install the fuel inlet pipe onto the supply pump and common rail.

      Note

      Install the pipe and union nut vertically, not at a tilt.

    2. Tighten the supply pump with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the common rail side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 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. Using a wrench (17 mm), hold the supply pump nut, using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the supply pump side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 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.

    5. Connect the No. 2 fuel hose.

    6. Connect the nozzle leakage pipe and install a new retainer spring onto the supply pump.

    7. A0118BYE02
      Text in Illustration
      *a Front Direction

      Connect the 2 connectors.

    8. Connect the harness bracket with bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    9. Connect the 2 fuel hoses.

  4. INSTALL NO. 2 INJECTION PIPE CLAMP


    1. A0118JH

      Install both sides of the No. 2 injection pipe clamp with the nut as shown in the illustration.

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

  5. INSTALL NO. 1 EGR COOLER BRACKET


    1. Install the No. 1 EGR cooler bracket with the 2 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    2. Connect the vacuum hose.

  6. INSTALL EGR WITH COOLER PIPE ASSEMBLY

    Click here

  7. BLEED AIR FROM FUEL SYSTEM

    Click here

  8. INSPECT FOR FUEL LEAK


    1. Connect an intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

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

    5. Perform the Active Test.

      Intelligent Tester Display Test Details Control Range Diagnostic Notes
      Test the Fuel Leak Pressurize common rail internal fuel pressure, and check for fuel leaks Stop/Start

      Perform inspection of the high pressure fuel system.

      Test is possible when the following conditions are met:


      • Warmed up engine.

      • Vehicle is stopped.

      • Battery voltage is 12 V or more.

      • PM regeneration is not operating.

      • Engine speed is less than 4000 rpm.

      Results of real-vehicle check:


      • Engine Speed: 2702 rpm


      • Fuel Pressure: 108570 kPa


      • Target Common Rail Pressure: 105500 kPa


      • Target Pump SCV Current: 1.2 A


      • MAP: 127 kPa


      • MAF: 28 g/sec.