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
).
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![](../../../img/13/AC503013AB00ENG.png)
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1.Using special tool
sprocket holder (MB992048), lock the injection pump
sprocket, and then
loosen the injection pump sprocket mounting nut.
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![](../../../img/13/AC502178AB00ENG.png)
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2.Using the special tools
below, remove the injection pump
sprocket.
- Injection pump sprocket puller (MB992098)
- Crank pulley puller (MB992099)
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![](../../../img/13/AC901507AB00ENG.png)
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Using special tool fuel injection
pipe wrench (MB992188), remove the fuel injection pipe
assembly No.1 to No.4.
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![](../../../img/13/AC502866AB00ENG.png)
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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.
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![](../../../img/13/AC502867AB00ENG.png)
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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.
|
|
![](../../../img/13/AK600656AB00ENG.png)
![](../../../img/13/AK600668AB00ENG.png)
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5.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 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
|
![](../../../img/13/AC502867AB00ENG.png)
|
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.
|
|
![](../../../img/13/AK600656AB00ENG.png)
![](../../../img/13/AK600668AB00ENG.png)
|
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 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
|
|
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
|
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5.Tighten the fuel supply
pump pipe bolt.
|
![](../../../img/13/AC503013AB00ENG.png)
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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
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