![](../../../img/11/AK802846AC00ENG.png)
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caution |
Too much pulling the harness
bracket can possibly damage
the insertion portion at the rocker cover
side.
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![](../../../img/11/AC809092AB00ENG.png)
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Using the special tool fuel
injection pipe wrench (MB992188), remove the fuel injector
assembly side of fuel injection tube No. 3 and No.
4.
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![](../../../img/11/AK802854AC00ENG.png)
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1.Insert the special tool
Nozzle gasket remover (MB992333) into the fuel injector
installation
hole of the cylinder head. 2.As shown in the
illustration, turn the tool dial. Hold the nozzle gasket and
pull
out the tool.
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1.Install the O-ring to the
fuel supply pump assembly.
note |
Make sure that it is free from
dust nor cracks.
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2.Install the fuel supply
pump assembly to the cylinder head and the rear camshaft
bearing
cap.
note |
At that time, match the axis
of the fuel supply pump assembly to the coupling
shape.
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3.After temporarily
tightening the fuel supply pump assembly, tighten it
gradually not
once, but two or three times to the specified torque of 25
± 7 N·m.
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![](../../../img/11/AC900270AB00ENG.png)
![](../../../img/11/AC900203AB00ENG.png)
![](../../../img/11/AC900204AB00ENG.png)
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1.Follow the following
procedures to clean the fuel injector (nozzle) and the
cylinder
head (fuel injector insertion hole). (1)
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caution |
Do not clean the
nozzle spray hole.
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Use the resin paddle and remove the carbon deposits
from the fuel injector area "A" shown
in the illustration. (2)
Carburettor cleaner (MZ100139) or the equivalent product to
the injector spray hole. (3)
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caution |
Do not touch the
nozzle spray hole by hand or wipe it
by waste cloth.
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Leave the injector spray hole for a while to melt
the carbon deposits. And then blow air. (4)
Insert the special tool ornament remover (MB990784) into the
cylinder head (fuel injector
insertion hole). Remove carbon deposits. (5)
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caution |
Blow air at the
piston top dead centre to prevent
carbon deposits
from increasing on the cylinder
wall.
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Remove the special tool MB990784. Blow air and
remove carbon deposits from the cylinder
head (fuel injector insertion hole). (6)
Check whether carbon deposits do not remain on the surface
contacted with the fuel
injector nozzle gasket.
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note |
Repeat the
procedures, from (4) to (6), until
carbon deposits are thoroughly
removed.
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caution |
- The fuel injection pipe can be removed
and reinstalled up to
five times. To count how many times the
fuel injection pipe is reinstalled,
record the number
of the reinstallation histories on the
service booklet by adding this latest
number, usually
"1", to the previous one. Use a new
injection pipe when the number of total
reinstallation is
five times, or when the injector or
common rail assembly is replaced. In
this case, record "New
fuel injection pipe (number of total
reinstallation: zero)" on the service
booklet.
- If a fuel leak is present in the fuel
injection pipe and fuel injection pipe
set
once, do not reuse it and replace with a
new one.
- If the fuel injector assembly, common
rail assembly or supply pump assembly is
replaced,
the contact surface (seal surface)
between the fuel injection pipe and fuel
injection pipe set,
and the other side component is changed,
do not reuse the fuel injection pipe and
fuel supply
pump pipe and replace with a new
one.
- Reinstall the fuel injection pipe,
making sure that the seal surface is
free of
foreign materials and matching the pipe
contact.
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![](../../../img/11/AK900100AC00ENG.png)
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2.Temporarily install the
fuel injector and the injector holder. (1)
Thoroughly remove foreign materials such as carbon deposits
between the nozzle gasket
and the cylinder head seating surface, also between the
nozzle gasket and the injector. (2)
Apply oil to the tightening bolt threads of the injector
holder, also to the flange
reverse surface. (3)
Insert the injector holder into the fuel injector from the
top. Turn the injector
holder 90° and install it. (4)
Set the nozzle gasket to the installation location of the
injector of the cylinder
head.
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note |
The nozzle gasket
does not distinguish the front side
from the reverse side. The oil
application
is not necessary.
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(5)
Insert the fuel injector into the installation location of
the cylinder head.
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note |
At that time,
insert the fuel injector as
perpendicularly as
possible.
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(6)
Set the bolt and the washer to the injector holder. Place
two bolts to the cylinder head
seating surface at the same time and temporarily fix them.
At that time, use the straight gauge
and check whether the tilt of the injector holder is within
2 mm in the left and right directions. (7)
Check whether foreign materials or rust does not stay at the
fuel feed threads of
the fuel injector, also at the fuel return area and the high
pressure pipe seating surface. 3.Temporary
installation of common rail assembly (1)
Temporarily install the common rail assembly to the cylinder
head with bolts. (The
bolt slightly touches the common rail installation
surface.)
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note |
At that time, hold
the rail body without holding the
pressure limiter of the common rail
assembly and the pressure
sensor.
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(2)
Make sure the thread portion of the common rail assembly and
the seat surface of the
high pressure pipe are free of foreign materials or
rust. 4.Temporarily install the fuel injection
pipe No.1 to No.4. Temporarily install the
supply pump pipe B and the fuel return pipe. (1)
Align the fuel injection pipe centre axis with the other
side components (common rail
assembly and fuel injector assembly) centre axis to install
the fuel injection pipe No.1 to
No.4. Then, tighten the flare nut temporarily until the
tip of pipe (seal surface) contacts
with the other side components.
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note |
When the fuel
injection pipe is installed, tighten
the flare nut while shaking the pipe
lightly to align the centre axis of
both components.
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(2)
Use bolts and temporarily fix the fuel return pipe to the
rocker cover. (3)
Use flare nuts and temporarily fix the supply pump pipe B to
the fuel injector and
the common rail assembly.
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note |
At that time,
check the flare nuts at the pipe
side smoothly rotate, and securely
align
the axis centres of the both pipe
ends that contact each
other.
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(4)
Use bolts and temporarily fix the clamp area of the supply
pump pipe B to the rocker
cover.
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![](../../../img/11/AK802838AC00ENG.png)
![](../../../img/11/AK900100AC00ENG.png)
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5.Install the fuel injector
and the injector holder. (1)
Tighten the injector holder bolt (at the front engine side)
to the tightening torque
of 1.1 ± 0.1 N·m. (2)
As shown in the illustration, make a paint mark to the bolt
top. Based on the paint mark of the bolt, make the paint
marks to the injector holder respectively:
90° in the direction of tightening the bolt on the
engine front side and 180° in
the direction of tightening the bolt on the rear engine
side. (3)
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caution |
- When the tightening
angle is smaller than the
specified tightening angle,
the appropriate tightening
capacity cannot
be secured.
- When the tightening angle is
larger than the specified
tightening angle, remove
the bolt to start from the
beginning again according to
the procedure.
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Tighten the engine rear side bolt 180°. Check
the paint mark of the injector
holder and that of the bolt are aligned. (4)
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caution |
The tilt of the
injector holder must be within 2 mm
in the left
and right directions. If the tilt is
larger than the specified value,
loosen the bolts and restart
from the beginning.
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Tighten the engine front side bolt 90°. Check
the paint mark of the injector
holder and that of the bolt are aligned.
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![](../../../img/11/AK900107AC00ENG.png)
![](../../../img/11/AK802977AC00ENG.png)
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6.Install the fuel injection
pipe No.1 to No.4. Install the supply pump pipe B. (1)
Use the special tool crowfoot wrench (MB992211). To the
temporary torque calculated
by the following calculation formula, tighten the flare nuts
of fuel injection tube set B at
the common rail assembly side as well as the fuel injection
tube No.1 to No.4. Tightening torque: (18
± 2) × {L ÷ (L +
25)} N·m
18 ± 2:
Tightening torque of the fuel injection
tube (unit: N·m) L: Distance between the
centre of a torque wrench drive and of its handle
(unit:
mm) 25: Length of pitch for special tool between
holes (unit: mm)
(2)
Using the special tool fuel injection pipe wrench
(MB992188), tighten the fuel injector
assembly side of fuel injection tube No. 3 and No. 4 and the
supply pump side of fuel injection
tube set B to the temporary tightening
torque. Tightening torque: 18 ± 2
N·m (3)
Use the special tool MB992211. To the specified torque
calculated by the following
calculation formula, tighten the flare nuts of fuel
injection tube set B at the common rail
assembly side as well as the fuel injection tube No.1 to
No.4. Tightening torque: (35 ± 5) ×
{L ÷ (L + 25)} N·m
35 ± 5: Tightening torque of
the fuel injection
tube (unit: N·m) L: Distance between the
centre of a torque wrench drive and of its handle
(unit:
mm) 25: Length of pitch for special tool between
holes (unit: mm)
(4)
Using the special tool MB992188, tighten the fuel injector
assembly side of the fuel
injection tube No. 3 and No. 4 and the supply pump side of
the fuel injection tube set B to
the specified torque. Tightening torque: 35
± 5 N·m (5)
Tighten the clamp area of the supply pump pipe B to the
specified torque of 11 ± 3
N·m. 7.Install the fuel return pump. (1)
Use the gasket and the eye bolt, and tighten the fuel return
pipe together with the
pressure limit of the common rail assembly to the specified
torque of 20 ± 2 N·m. (2)
Tighten the fuel return pipe together with the rocker cover
to the specified torque
of 10 ± 2 N·m. (3)
Install the fuel return hose to the fuel return pipe with
the hose clip. 8.Temporarily install the common
rail assembly. (1)
To the specified torque of 25 ± 7 N·m, tighten
the common rail assembly
that is temporarily tightened.
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1.Temporarily install the
clamp of the supply pump pipe A to the rocker cover with
bolts.
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![](../../../img/11/AK802976AC00ENG.png)
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2.Use Special tool Fuel
injection pipe wrench (MB992188) to install the supply pump
pipe
A. 3.Tighten the nuts of the supply pump pipe A to
the temporary torque of 18 ± 2
N·m at the common rail side.
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![](../../../img/11/AC809093AB00ENG.png)
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4.Use the special tool fuel
injection pipe wrench (MB992211), Tighten the nuts of the
supply
pump pipe A at the common rail side to the temporary torque
calculated by the following calculation
formula. Tightening torque: (18 ± 2)
× {L ÷ (L + 25)} N·m
18 ± 2: Tightening torque of
the fuel injection
tube (unit: N·m) L: Distance between the
centre of a torque wrench drive and of its handle
(unit:
mm) 25: Length of pitch for special tool between
holes (unit: mm)
5.Tighten the
nuts of the supply pump pipe A at the fuel supply pump
assembly side to
the specified torque of 35 ± 5 N·m.
note |
Wrap around the fuel pipe with
a seal tape to prevent the fuel pipe from being
damaged.
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6.Tighten the nuts of the supply pump pipe A
at the common rail side to the specified
torque calculated by the following calculation
formula. Tightening torque: (35 ± 5)
× {L ÷ (L + 25)} N·m
35 ± 5: Tightening torque of
the fuel injection
tube (unit: N·m) L: Distance between the
centre of a torque wrench drive and of its handle
(unit:
mm) 25: Length of pitch for special tool between
holes (unit: mm)
7.Tighten the
clamp of the supply pump pipe A to the specified torque of
11 ± 3
N·m.
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1.Temporarily install the
fuel pipe to the fuel supply pump assembly with bolt and
washers.
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2.Temporarily install the
fuel pipe to the cylinder head with bolt.
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3.Tighten the bolt to the
specified torque of 17 ± 2 N·m at the fuel
supply pump assembly side.
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4.Tighten the cylinder head
side bolt to the specified torque of 14 ± 3
N·m.
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5.At the last, check the
fuel does not leak from the connection portion of each pipe
and from the gasket.
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