REMOVAL AND INSTALLATION


caution
  • The reinstallation histories of the removed fuel injection pipe and fuel supply pump pipe are up to five times. To count how many times the fuel injection pipe and fuel supply pump pipe are 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 or fuel supply pump pipe when the total reinstallation history numbers reach five times, or when the fuel injector assembly, common rail assembly or supply pump assembly is replaced. In this case, record "a new fuel injection pipe or fuel supply pump pipe, the number of the reinstallation histories is zero" on the service booklet.
  • If a fuel leak is present in the fuel injection pipe and fuel supply pump pipe 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 supply pump pipe, 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.
  • When the injection pipe 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.
  • When the supply pump is replaced, perform the supply pump correction learning (Refer to GROUP 00 - Precautions before Service, What the Common Rail Engine Learns ).
Pre-removal Operation
  • Engine Cover Removal (Refer to GROUP 11G - Engine Assembly ).
  • Inlet Manifold Removal (Refer to GROUP 15 - Inlet Manifold ).
  • EGR Cooler Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ).

 Post-installation Operation
  • EGR Cooler Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
  • Inlet Manifold Installation (Refer to GROUP 15 - Inlet Manifold ).
  • Fuel Line Leak Check (Refer to ).
  • Engine Cover Installation (Refer to GROUP 11G - Engine Assembly ).




Supply pump assembly removal steps


·
 Timing belt (Refer to GROUP 11G - Timing Belt ).
<<A>>
 >>D<<
 1.
 Injection pump sprocket


2.
 Fuel return hose


3.
 Fuel inline hose
<<B>>
 >>C<<
 4.
 Fuel supply pump pipe

>>C<<
 5.
 Supply pump assembly



Fuel injection pipe removal steps


2.
 Fuel return hose


3.
 Fuel inline hose
<<B>>
 >>B<<
 4.
 Fuel supply pump pipe
<<C>>
 >>B<<
 6.
 Fuel injection pipe



Common rail assembly removal steps


2.
 Fuel return hose


3.
 Fuel inline hose
<<B>>
 >>C<<
 4.
 Fuel supply pump pipe
<<C>>
 >>A<<
 6.
 Fuel injection pipe

>>A<<
 7.
 Eye bolt

>>A<<
 8.
 Fuel return gasket

>>A<<
 9.
 Common rail assembly

>>A<<
 10.
 Eye bolt

>>A<<
 11.
 Fuel return gasket

>>A<<
 12.
 Fuel return pipe

REMOVAL SERVICE POINTS

<<A>> INJECTION PUMP SPROCKET REMOVAL

1.Using special tool sprocket holder (MB992048), lock the injection pump sprocket, and then loosen the injection pump sprocket mounting nut.

2.Using the special tools below, remove the injection pump sprocket.

  • Injection pump sprocket puller (MB992098)
  • Crank pulley puller (MB992099)

<<B>> FUEL SUPPLY PUMP PIPE REMOVAL
caution When removing the fuel supply pump pipe, the fuel pressure in the fuel line is high. Thus, wait for 3 minutes or longer after the engine stops, and cover the fuel supply pump pipe with a rag or similar materials to prevent the fuel splash, and then disconnect the fuel supply pump pipe.

<<C>> FUEL INJECTION PIPE REMOVAL


Using special tool fuel injection pipe wrench (MB992188), remove the fuel injection pipe assembly No.1 to No.3. As for removal of fuel injection pipe assembly No.4, use special tool fuel injection pipe wrench (MB992188) for the common rail assembly side, and use special tool crowfoot wrench (MB992211) for the injector assembly side.

INSTALLATION SERVICE POINTS

>>A<< FUEL RETURN PIPE/FUEL RETURN GASKET/EYE BOLT/COMMON RAIL ASSEMBLY/FUEL INJECTION PIPE INSTALLATION

1.Temporarily tighten the fuel return pipe with bolts.
2.Tighten the eye bolt and the fuel return gasket located at the cylinder head side to the specified torque.

    Tightening torque:

      17 ± 2 N·m

3.
caution
  • When operating, do not support the common rail assembly by holding the rail pressure limiter and the 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 tighten the common rail assembly with bolts, holding the common rail assembly.
4.Align the fuel injection pipe centre axis with the other side components (fuel injector assembly and common rail assembly) centre axis to install the fuel injection pipe. Then, tighten the flare nut temporarily until the tip of pipe (seal surface) contacts with the other side components.
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.



5.Using special tools fuel injection pipe wrench (MB992188) <Fuel injection pipe No.1 to No.3 and common rail assembly side of fuel injection pipe No.4> or crowfoot wrench (MB992211) <Injector assembly side of fuel injection pipe No.4>, start tightening the fuel injector assembly side flare nut in the fuel injection pipe, and then tighten the fuel injector assembly side flare nut and common rail assembly side flare nut alternately in several steps to the specified torque.
Tightening torque: 35 ± 5 N·m
6.Tighten the common rail assembly to the specified torque.
Tightening torque: 24 ± 4 N·m
7.Tighten the eye bolt and the fuel return gasket located at the common rail assembly side to the specified torque.
Tightening torque: 20 ± 2 N·m
8.Tighten the fuel return pipe to the specified torque.
Tightening torque: 10 ± 2 N·m
9.Tighten the bolts of the fuel injection pipe to the specified torque.
Tightening torque: 10 ± 2 N·m
10.Tighten the common rail assembly side flare nut in the fuel supply pump pipe and the supply pump assembly side flare nut alternately in several steps to the specified torque.
Tightening torque: 35 ± 5 N·m

>>B<< FUEL INJECTION PIPE/FUEL SUPPLY PUMP PIPE INSTALLATION

1.
caution
  • When operating, do not support the common rail assembly by holding the rail pressure limiter and the 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.
Loosen the common rail assembly mounting bolts so that the common rail assembly will be in the temporarily installed state.
2.Align the fuel injection pipe centre axis with the other side components (fuel injector assembly and common rail assembly) centre axis to install the fuel injection pipe. Then, tighten the flare nut temporarily until the tip of pipe (seal surface) contacts with the other side components.
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.


3.Using special tool fuel injection pipe wrench (MB992188), start tightening the fuel injector assembly side flare nut in the fuel injection pipe, and then tighten the fuel injector assembly side flare nut and common rail assembly side flare nut alternately in several steps to the specified torque.
Tightening torque: 35 ± 5 N·m

note Use the special tool crowfoot wrench (MB992211) to tighten the flare nut at the injector assembly side of the fuel injection pipe No.4 so that the nut does not interfere with the heater hose.
4.Tighten the common rail assembly to the specified torque.
Tightening torque: 24 ± 4 N·m
5.Tighten the common rail assembly side flare nut in the fuel supply pump pipe and the supply pump assembly side flare nut alternately in several steps to the specified torque.
Tightening torque: 35 ± 5 N·m

>>C<< SUPPLY PUMP ASSEMBLY/FUEL SUPPLY PUMP PIPE INSTALLATION
1.Temporarily tighten the supply pump assembly with bolts.
2.Align the fuel supply pump pipe centre axis with the other side components (common rail assembly and supply pump assembly) centre axis to install the fuel supply pump pipe. Then, tighten the flare nut temporarily until the tip of pipe (seal surface) contacts with the other side components.
note When the fuel supply pump pipe is installed, tighten the flare nut while shaking the pipe lightly to align the centre axis of both components.
3.Tighten the common rail assembly side flare nut in the fuel supply pump pipe and the supply pump assembly side flare nut alternately in several steps to the specified torque.
Tightening torque: 35 ± 5 N·m
4.Tighten the supply pump assembly bolts to the specified torque.
Tightening torque: 24 ± 4 N·m
5.Tighten the fuel supply pump pipe bolt.

>>D<< INJECTION PUMP SPROCKET INSTALLATION

In the same manner as for removal, using special tool sprocket holder (MB992048), lock the injection pump sprocket, and then tighten the injection pump sprocket mounting nut to the specified torque.
Tightening torque: 64 ± 5 N·m