FUEL SUPPLY PUMP(w/ 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 sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.

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

PROCEDURE

  1. INSTALL NO. 3 NOZZLE LEAKAGE PIPE

    1. A355157C01

      *1

      Gasket

      *a

      45°

      *b

      Up

      Install a new gasket and No. 3 nozzle leakage pipe to the supply pump assembly with the union bolt.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

      Note:

      • Install the gasket within the area shown in the illustration.

      • A349638C01

        *a

        Correct

        *b

        Incorrect

        When installing, make sure the detent portion of the No. 3 nozzle leakage pipe is in the location as shown in the illustration.

  2. INSTALL NO. 4 NOZZLE LEAKAGE PIPE

    1. A355156C01

      *1

      Gasket

      *a

      45°

      *b

      Up

      Install a new gasket and No. 4 nozzle leakage pipe to the supply pump assembly with the union bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Note:

      Install the gasket within the area shown in the illustration.

  3. INSTALL SUPPLY PUMP ASSEMBLY

    1. A349637

      Install the supply pump drive coupling to the supply pump assembly.

    2. A348741

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

      Note:

      If reusing the supply pump assembly, be sure to inspect the O-ring.

    3. Install the supply pump assembly to the cylinder head sub-assembly with the 3 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  4. INSTALL FUEL PUMP PROTECTOR

    1. Install the fuel pump protector to the supply pump assembly with the 2 bolts.

      10.3 N*m

      105 kgf*cm

      8 ft.*lbf

  5. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

    1. A353573N01

      Install the No. 2 nozzle leakage pipe to the cylinder head cover sub-assembly and supply pump assembly with the 2 bolts.

      Bolt (A)

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Bolt (B)

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

    2. Connect the fuel temperature sensor connector.

    3. Connect the No. 2 fuel hose to the No. 2 nozzle leakage pipe and slide the clip to secure it.

    4. Install the wiring harness clamp bracket to the fuel pump protector with the bolt.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    5. Engage the clamp to connect the wire harness to the wiring harness clamp bracket.

    6. Connect the supply pump assembly connector.

    7. Connect the fuel hose to the No. 4 nozzle leakage pipe and slide the clip to secure it.

  6. CONNECT NO. 1 FUEL HOSE

    1. A353567C01

      *a

      Front

      *b

      120°

      Connect the No. 1 fuel hose to the No. 3 nozzle leakage pipe and slide the clip to secure it.

      Tip:

      Engage the clip within the area shown in the illustration.

    2. Engage the clamp.

  7. CONNECT NO. 2 FUEL HOSE

    1. A353566C01

      *a

      Up

      *b

      120°

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

      Tip:

      Engage the clip within the area shown in the illustration.

  8. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  9. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

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  10. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

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  11. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

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  12. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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  13. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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  14. INSTALL NO. 1 GLOW PLUG CONNECTOR

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  15. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  16. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  17. PERFORM INITIALIZATION AND REGISTRATION

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  18. BLEED AIR FROM FUEL SYSTEM

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  19. INSPECT FOR FUEL LEAK

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  20. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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