REMOVAL AND INSTALLATION

caution

When the injector assembly is replaced, register the injector identification code and perform the fuel injection learning (Refer to GROUP 00 - Precautions Before Service - What The Common Rail Engine Learns

Pre-removal Operation

Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
Engine Cover Removal (Refer to GROUP 11G - Engine Assembly ).

Post-installation Operation

Engine Cover Installation (Refer to GROUP 11G - Engine Assembly ).
Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).

			Removal steps
		1.	Breather hose
		·	A/T fluid level gauge and guide assembly (Refer to GROUP 23A - Transmission Assembly ) <A/T>.
		·	Engine oil level gauge and guide assembly (Refer to GROUP 11G - Oil Pan and Oil Strainer ).
		2.	Fuel hose
		3.	Fuel return hose
		4.	Fuel return B pipe assembly
<<A>>	>>D<<	5.	Fuel supply pump pipe assembly
		·	Air inlet pipe <4M41> (Refer to GROUP 15 - Inlet Manifold ).
<<B>>	>>D<<	6.	Fuel injection No.4 pipe assembly
<<B>>	>>D<<	7.	Fuel injection No.3 pipe assembly
<<B>>	>>D<<	8.	Fuel injection No.2 pipe assembly
<<B>>	>>D<<	9.	Fuel injection No.1 pipe assembly
		10.	Rail pressure sensor connector
		11.	Harness clamp
<<C>>	>>D<<	12.	Common rail assembly
	>>D<<	13.	Gasket
	>>D<<	14.	Fuel pipe bracket
	>>D<<	15.	Fuel return A pipe assembly
	>>D<<	16.	Gasket
		17.	Injector assembly connector
		18.	Rocker cover assembly
		19.	Rubber assembly
	>>C<<	20.	Oil seal
	>>B<<	21.	Oil seals
		22.	Harness bracket
		23.	Rocker cover gasket
	>>A<<	24.	Fuel leakage pipe assembly
	>>A<<	25.	Gasket
	>>A<<	26.	Injector holder bolt
	>>A<<	27.	Injector supporter
	>>A<<	28.	Support bolt
	>>A<<	29.	Injector assembly
		30.	Gasket
		31.	Pivot boss
		32.	Pivot bar

REMOVAL SERVICE POINTS

<<A>> FUEL SUPPLY PUMP PIPE ASSEMBLY REMOVAL

caution

Because the fuel pressure in the fuel line is high, wait for 3 minutes or longer after the engine is stopped. Then, cover the fuel supply pump pipe with a rag or similar materials to prevent the fuel spill, and then disconnect the fuel supply pump pipe assembly.

<<B>> FUEL INJECTION PIPE ASSEMBLY REMOVAL

Using special tool fuel injection pipe wrench (MB992188), remove the fuel injection pipe assembly No.1 to No.4.

<<C>> COMMON RAIL ASSEMBLY REMOVAL

caution

When operating, do not support the common rail assembly by holding the rail pressure limiter and the rail pressure sensor at both ends.
Before the installation, make sure that there is no foreign object or rust to the thread and to the high-pressure pipe sheet surface.

INSTALLATION SERVICE POINTS

>>A<< INJECTOR ASSEMBLY/SUPPORT BOLT/INJECTOR SUPPORTER/INJECTOR HOLDER BOLT/GASKET/FUEL LEAKAGE PIPE ASSEMBLY INSTALLATION

1.Tighten the support bolts to the specified torque.
Tightening torque: 30.0 ± 1.5 N·m

2.Install the gasket, injector assembly and pivot boss.

3.Apply the engine oil to the bearing surface and thread of injector supporter holder bolts.
4.Temporarily fix the injector supporters.
5.Install the gaskets to the fuel leakage pipe assembly.
6.Tighten the eye bolts at the Injector assembly side to the specified torque.
Tightening torque: 15 ± 2 N·m
7.Tighten the eye bolt at the cylinder head side to the specified torque.
Tightening torque: 15 ± 2 N·m
8.Tighten the fuel leakage pipe assembly mounting bolt to the specified torque.
Tightening torque: 24 ± 3 N·m

9.Tighten the injector holder bolts according to the following procedure.
(1) Tighten the injector holder bolts to 10 ± 1 N·m.
(2)

caution

If the bolt is tightened less than the specified lower limit of 80 degree angle, the bolt may become loose. Be sure to tighten correctly.
If the bolt is tightened in excess of the specified upper limit of 85 degree angle, loosen the bolt completely and repeat the entire procedures.

Using special tool angle gauge (MB991614), tighten the injector holder bolts in the illustrated sequence by a further 80 to 85 degree angle.

>>B<< OIL SEAL INSTALLATION

Using a proper socket wrench, the oil seal is pressed and fit into the rocker cover.

>>C<< OIL SEAL INSTALLATION

Use the following special tools to press-fit the oil seal.

oil seal installer (MB992104)
handle (MB992075)

>>D<< GASKET/FUEL RETURN A PIPE ASSEMBLY/FUEL PIPE BRACKET/COMMON RAIL ASSEMBLY/FUEL INJECTION PIPE ASSEMBLY/FUEL SUPPLY PUMP PIPE ASSEMBLY INSTALLATION

caution

The reinstallation histories of the removed fuel injection pipe assembly and fuel supply pump pipe assembly are up to five times. To count how many times the fuel injection pipe assembly and fuel supply pump pipe assembly 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 fuel injection pipe assembly and fuel supply pump pipe assembly when the total reinstallation history numbers reach five times, or when the supply pump assembly or common rail assembly is replaced. In this case, record "a new fuel injection pipe assembly and fuel supply pump pipe assembly, the number of the reinstallation histories is zero" on the service booklet.
When the fuel injection pipe assembly and fuel supply pump pipe assembly 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 and temporarily fix the gaskets to the fuel return A pipe assembly.

2.Using the eye bolt, tighten the cylinder head side of fuel return A pipe assembly to the specified torque.
Tightening torque: 20.2 ± 2.4 N·m

caution

When operating, do not support the common rail assembly by holding the rail pressure limiter and the rail pressure sensor at both ends.
Before the installation, make sure that there is no foreign object or rust to the thread and to the high-pressure pipe sheet surface.

Temporarily fix the common rail assembly.
4.Temporarily fix from the fuel injection pipe assembly No. 1 to No. 4.

5.Using special tool fuel injection pipe wrench (MB992188), tighten the injector assembly side of fuel injection pipe assembly No. 1 to No. 4 to the specified torque.
Tightening torque: 35 ± 5 N·m

note

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

6.Using special tool (MB992188), tighten the common rail assembly side of fuel injection pipe assembly No. 1 to No. 4 to the specified torque.
Tightening torque: 35 ± 5 N·m

note

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

7.Using the eye bolt, tighten the common rail assembly side of fuel return A pipe assembly to the specified torque.
Tightening torque: 20.2 ± 2.4 N·m
8.Tighten the common rail assembly mounting bolt to the standard torque.
9.Tighten the bolt of the inlet manifold assembly installation point of the fuel return A pipe assembly to the standard torque.
10.Install the fuel pipe bracket.
11.Tighten the bolt of the fuel pipe bracket installation point of the fuel return A pipe assembly to the standard torque.
12.Install the air inlet pipe (Refer to GROUP 15 - Inlet Manifold <4M41>

).
13.Install the fuel supply pump pipe assembly.
14.Tighten the bolt of the fuel supply pump pipe assembly to the specified torque.
Tightening torque: 35 ± 5 N·m