FUEL SUPPLY PUMP(w/o Glow Plug Controller) INSTALLATION

CAUTION / NOTICE / HINT

Note:

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

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

PROCEDURE

  1. INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING

    1. A227261C01

      *1

      Camshaft

      *2

      No. 1 Supply Pump Drive Coupling

      Install the No. 1 supply pump drive coupling into the camshaft as shown in the illustration.

  2. INSTALL SUPPLY PUMP ASSEMBLY

    Note:

    When installing, clean the sealing surfaces of the fuel inlet pipe sub-assembly, supply pump assembly and common rail assembly.

    1. A202920

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

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

    3. A202918

      Temporarily install the supply pump assembly with the 3 bolts.

  3. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A125732C04

    *a

    Correct

    *b

    Incorrect
    Note:

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

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

    1. A236082

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

      Note:

      Install the fuel inlet pipe sub-assembly and union nut vertically, not at a tilt.

    2. Tighten the supply pump assembly with the 3 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    3. Using a 17 mm union nut wrench, tighten the union nut on the common rail assembly side.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

      Note:

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

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    4. Using a 17 mm union nut wrench, tighten the union nut on the supply pump assembly side while holding the supply pump assembly with a 17 mm wrench.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

      Note:

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

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    5. A202917

      Connect the fuel hose and slide the clip to secure it.

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

    7. A199697

      Connect the 2 connectors to the supply pump assembly.

    8. A299908C01

      *a

      Upper

      *b

      LH Side

      *c

      90°

      Connect the No. 2 fuel hose and slide the clip to secure it.

      Note:

      Engage the clip within the area shown in the illustration.

    9. A299909C01

      *a

      Upper

      *b

      Front

      *c

      90°

      Connect the No. 1 fuel hose and slide the clip to secure it.

      Note:

      Engage the clip within the area shown in the illustration.

  4. INSTALL NO. 1 EGR COOLER BRACKET

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  5. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  6. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  7. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY

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  8. BLEED AIR FROM FUEL SYSTEM

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  9. INSPECT FOR FUEL LEAK

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