REMOVAL AND INSTALLATION


caution
  • When the supply pump is replaced, use the M.U.T.-III to initialise the learning value (Refer to GROUP 00 - Precautions Before Service, Initialisation Procedure for Learning Value in Common Rail Engine ).
  • 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
  • Harness bracket Removal (Refer to ).
  • Throttle Body Assembly Removal (Refer to ).
  • EGR Cooler Removal (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Vacuum Pump Assembly Removal (Refer to GROUP 11E - Vacuum Pump ).

 Post-installation Operation
  • Vacuum Pump Assembly Installation (Refer to GROUP 11E - Vacuum Pump ).
  • EGR Cooler Installation (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Throttle Body Assembly Installation (Refer to ).
  • Harness bracket Installation (Refer to ).
  • Fuel Line Leak Check (Refer to )




Removal steps


1.
 Fuel hose D connection


2.
 Fuel inlet pipe assembly


3.
 Fuel inlet hose


4.
 Fuel return hose connection


5.
 Fuel return pipe assembly A


6.
 Fuel return hose E


7.
 Fuel return hose F

>>B<<
 8.
 Supply pump pipe

>>A<<
 9.
 Supply pump mounting bolt
<<A>>
 >>A<<
 10.
 Supply pump assembly

REMOVAL SERVICE POINT

<<A>> SUPPLY PUMP ASSEMBLY REMOVAL
When you pull out the supply pump gear from the supply pump assembly, loosen the supply pump gear mounting nut according to the procedure below in advance.

1.Use the following special tools to support the crankshaft pulley.

  • Front hub and flange yoke holder (MB990767)
  • Pin (MD998719)
2.Loosen the supply pump gear mounting nut.

INSTALLATION SERVICE POINTS

>>A<< SUPPLY PUMP ASSEMBLY / SUPPLY PUMP MOUNTING BOLT INSTALLATION

1.Position the key slit on the supply pump gear as shown.
2.Remove all the residual sealant from the threaded hole in the cylinder block.
When the supply pump mounting bolt is reused, carefully remove the residual sealant from the bolt thread.

3.When the supply pump mounting bolt is reused, apply the sealant as shown.
Specified sealant: ThreeBond 2403 or equivalent

4.Insert the supply pump assembly through the vacuum pump opening in the timing chain case so that the slit on the supply pump gear is aligned with the oil channel hole on the timing chain case.
5.Tighten the supply pump mounting bolts to the specified torque.
Tightening torque: 25 ± 7 N·m
6.If the supply pump gear mounting nut is loosened, use the same special tools as during removal to tighten the supply pump gear mounting nut to the specified torque.

  • Front hub and flange yoke holder (MB990767)
  • Pin (MD998719)
Tightening torque: 83 ± 5 N·m

>>B<< SUPPLY PUMP PIPE INSTALLATION
1.
caution
  • The removed supply pump pipe can be reassembled up to five times. To count the number of supply pump pipe reassembly, record it by adding the reassembly number of this time (once usually) to the previous number of reassembly written on the maintenance handbook. When the number of the previous reassembly reaches 5 or when the supply pump assembly or common rail assembly is replaced, always use a new supply pump pipe. At that time, write "New (0 times)" in the maintenance handbook.
  • If a fuel leak is present in the supply pump pipe and supply pump pipe set once, do not reuse it and replace with a new one.
  • If the supply pump assembly, common rail assembly is replaced, the contact surface (seal surface) between the supply pump pipe and supply pump pipe set, and the other side component is changed, do not reuse the supply pump pipe and replace with a new one.
  • When reassembling the supply pump pipe, remove the foreign material attached on the sealing surface, and install it with the contacting point of the pipe aligned.
Align the supply pump pipe centre axis with the other side components (common rail assembly and supply pump assembly) centre axis to install the 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 supply pump pipe is installed, tighten the flare nut while shaking the pipe lightly to align the centre axis of both components.
2.Using the special tool MB992188 or equivalent tool, tighten the supply pump side of the supply pump pipe to the temporary tightening torque.
Tightening torque: 18 ± 2 N·m

3.Using the special tool crowfoot wrench (MB992211), tighten the common rail assembly side of the supply pump pipe to the temporary tightening torque calculated by the following formula.
Tightening torque: (18 ± 2) × {L ÷ (L + 25)} N·m

    18 ± 2: Tightening torque of the fuel injection pipe (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 or equivalent tool, tighten the supply pump side of the supply pump pipe to the specified torque.
Tightening torque: 35 ± 5 N·m
5.Using the special tool MB992211, tighten the common rail assembly side of the supply pump pipe to the specified torque calculated by the following formula.
Tightening torque: (35 ± 5) × {L ÷ (L + 25)} N·m

    35 ± 5: Tightening torque of the fuel injection pipe (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)
6.Check that no fuel is leaked from the supply pump pipe connection area.