FUEL SUPPLY PUMP (w/ EGR Cooler) INSTALLATION

INSTALL SUPPLY PUMP ASSEMBLY
1. Check that the injection gear in the timing gear case moves back and forth smoothly.
2. Install a new O-ring to the pump.
3. Apply a light coat of engine oil to the O-ring.
4. Align the set key on the drive shaft with the groove of the injection gear.
5. Install the pump with the 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Set a new O-ring.
7. Using SST, hold the crankshaft pulley and install the set nut.
  
  SST
  
  09213-58013
  
  09330-00021
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
8. Using a dial indicator, measure the thrust clearance of the injection pump shaft by moving the pump drive shaft pulley back and forth.
  
  Thrust clearance
  
  0.15 to 0.55 mm (0.0059 to 0.0217 in.)
  
  If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.
9. Connect the 2 connectors.
10. Connect the 2 fuel hoses.
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
1. Temporarily install the fuel inlet pipe with the union nuts.
  Note
  
  If the supply pump is replaced, the fuel inlet pipe must be replaced.
  
  Keep the fuel inlet pipe free of foreign matter.
2. Install a new O-ring to the oil level gauge guide, and install the oil level gauge guide to the cylinder block.
  
  Note
  
  Apply a coat of engine oil to the O-ring.
3. Temporarily install the stay of the oil level gauge guide to the intake manifold with the bolt.
4. Install the clamp with the bolt.
  
  Note
  
  Install the clamp so that the fuel inlet pipe marking can be seen on both sides of the clamp.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
5. Tighten the bolt of the oil level gauge guide stay.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
6. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.
  
  Torque:
  
  without union nut wrench
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  with union nut wrench
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.
  
  Make sure union nut wrench and wrench are connected in a straight line.
7. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the supply pump side.
  
  Torque:
  
  without union nut wrench
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  with union nut wrench
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
  Tech Tips
  - Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.
  - Make sure union nut wrench and wrench are connected in a straight line.
INSTALL TIMING BELT
1. Install the timing belt Click here.
INSTALL RADIATOR ASSEMBLY
1. Install the radiator assembly Click here.
ADD AUTOMATIC TRANSMISSION FLUID
ADD FUEL
TIGHTEN FUEL TANK CAP ASSEMBLY
BLEED AIR FROM FUEL SYSTEM
1. 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. 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.
  
  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.
13. Clear the DTCs Click here.
  
  Tech Tips
  
  It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.
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.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
CHECK FUEL SUPPLY PUMP INITIALIZATION
1. Initialize the fuel supply pump Click here.
START ENGINE
CHECK ENGINE COOLANT LEAKS
Note

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 to the radiator reservoir.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17.1 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 cylinder block and head.
CHECK FOR OIL LEAKS
CHECK FOR FUEL LEAKS
CAUTION:
- During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
- During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.
1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.
2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.
3. Disconnect the return hose from the common rail.
4. Start the engine and check for fuel leaks from the return pipe.
  
  If there is fuel leakage, replace the common rail.
5. Connect the intelligent tester to the DLC3.
6. Start the engine and push the intelligent tester main switch ON.
7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.
8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
9. Check that there are no leaks from any part of the fuel system.
  
  Note
  
  A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
  
  If there is fuel leakage, repair or replace parts as necessary.
10. Reconnect the return hose to the common rail.
INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)
1. Install the under cover with the 4 bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)
1. Install the under cover with the 4 bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }