REMOVAL AND INSTALLATION

			Removal steps
<<A>>	>>D<<	1.	Oil pressure switch
		2.	Oil pipe assembly
		3.	Fuel supply pump holder bracket
		4.	Fuel supply pump pipe assembly
	>>C<<	5.	Fuel supply pump assembly and holder
		6.	Fuel supply pump holder gasket
<<B>>	>>B<<	7.	Fuel supply pump gear
<<B>>	>>B<<	8.	Idler gear B assembly
		9.	Idler shaft A
		10.	Fuel supply pump holder
		11.	Fuel supply pump assembly
		12.	O-ring
	>>A<<	13.	Fuel retune hose
	>>A<<	14.	Fuel pipe bracket
		15.	Fuel retune hose
	>>A<<	16.	Fuel injection pipe No.1
	>>A<<	17.	Fuel injection pipe No.2
	>>A<<	18.	Fuel injection pipe No.3
	>>A<<	19.	Fuel injection pipe No.4
	>>A<<	20.	Common rail assembly
	>>A<<	21.	Fuel retune pipe assembly

REMOVAL SERVICE POINTS

<<A>> OIL PRESSURE SWITCH REMOVAL

Using special tool Oil pressure switch socket wrench (MB992118), removal the oil pressure switch.

<<B>> FUEL SUPPLY PUMP GEAR / IDLER GEAR B ASSEMBLY REMOVAL

1.Using the special tool Supply pump gear stopper (MB992096), hold the fuel supply pump gear and idler gear B.
2.Remove the hold the fuel supply pump gear nut and idler gear B bolt.

3.Using the special tool Side bearing puller (MB990810), remove the fuel supply pump gear.

INSTALLATION SERVICE POINTS

>>A<< FUEL RETUNE HOSE / FUEL PIPE BRACKET / INJECTION PIPE CLAMP / FUEL INJECTION PIPE NO.1 TO NO.4 /COMMON RAIL ASSEMBLY / FUEL RETURN PIPE ASSEMBLY

caution

The reinstallation histories of the removed injection pipe and supply pump pipe are up to five times. To count how many times the injection pipe and supply pump is reinstalled, record the number of the reinstallation histories on the service booklet by adding this latest number of the histories, which is usually "1" to the previous one.Use a new injection pipe and supply pump when the total reinstallation history numbers reach five times, or when the supply pump or common rail is replaced. In this case, record "a new injection pipe and supply pump, the number of the reinstallation histories is zero" on the service booklet.

When the injection pipe and supply pump is reinstalled, confirm there is no foreign material on the seal surface or in the pipe and then install it not to deviate from the axis, fitting the seal surface.

1.Install the fuel return pipe assembly lightly with bolt onto the cylinder head by hand.

2.Install fuel return pipe assembly to the cylinder head with gasket, eye bolt to the specified torque to 20.2 ± 2.4 N·m.

3.A temporary tightening makes common rail assembly cylinder head.

note

At this time, do not hold the pressure limiter or pressure sensor of the common rail.

note

Before the installation, confirm there is neither foreign material nor a rust on the threads and the sealing surface of a high-pressure pipe.

4.Temporarily tighten the fuel injection pipe assembly No.1 to No.4 with nuts.

5.Tighten the fuel pipe assembly to the specified torque of 35 ± 5 N·m at injector assembly.

6.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly No.1 to No.4.
Tighten the fuel injection pipe assembly No.1 to No.4 to the specified torque of 35 ± 5 N·m at injector side.
7.Install fuel return pipe assembly to the common rail with gasket, eye bolt to the specified torque to 20.2 ± 2.4 N·m.
8.Tighten the common rail assembly to the specified torque 24 ± 4 N·m.

9.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly No.1 to No.4.
Tighten the fuel injection pipe assembly No.1 to No.4 to the specified to torque of 35 ± 5 N·m at common rail side.

note

When there is a fear that a bruise is put, wind sealing tape around the fuel pipe, to prevent damage.

10.Install fuel return pipe assembly to the common rail assembly with gasket, eye bolt to the specified torque to 20.2 ± 2.4 N·m.
11.Install fuel return hose to the fuel return pipe assembly with hose clip.
12.Tighten the fuel pipe bracket to the specified torque of 10 ± 2 N·m.
13.Tighten the fuel return pipe assembly to the specified torque of 10 ± 2 N·m.

>>B<< FUEL SUPPLY PUMP GEAR / IDLER GEAR B ASSEMBLY INSTALLATION

1.Using the special tool Supply pump gear stopper (MB992096), hold the fuel supply pump gear and idler gear B.
2.Torque the fuel supply pump gear nut to the specified torque 64 ± 5 N·m.
3.Torque the idler gear B bolt to the specified torque 43 ± 2 N·m.

>>C<< FUEL SUPPLY PUMP ASSEMBLY AND HOLDER INSTALLATION

1.Turn the crankshaft clockwise to bring No. 1 cylinder to the top dead centre position.

2.Install the front plate after aligning the marks on the fuel supply pump gear and the fuel supply pump holder so that the fuel supply gear cannot be rotated.
It’s installed in front plate so that fuel supply pump gear doesn’t revolve together with a match mark of fuel supply pump gear and fuel supply pump holder.

3.A white paint is applied to the gears having the alignment mark of the fuel supply pump gear. Confirm the white paint on the fuel supply pump gear is aligned with the alignment mark of the front plate.

note

When viewed from the front, the alignment mark on the fuel supply pump gear deviates from that on the front plate by about 1 - 2 gears.

note

Confirm three marks of the supply pump gear are visible from the installation hole of the power steering pump.

>>D<< OIL PRESSER SWITCH INSTALLATION

caution

Be careful not to block the oil passage with sealant.

When reusing the sensor, apply the specified sealant to the threads.
Specified sealant:
3M™ ATD Part No. 8660 or equivalent or equivalent

2.Tighten the engine oil pressure switch together with the oil filter bracket to the specified torque, using special tool Oil pressure switch socket wrench (MB992118).
Tightening torque: 19 ± 3 N·m