REMOVAL AND INSTALLATION







Removal steps


1.
Injector insulator


2.
Fuel return hose A

>>D<<
3.
Fuel pipe
<<A>>

4.
Harness bracket


5.
Fuel return hose C


6.
Joint clip


7.
Fuel return joint A


8.
Fuel return joint B

>>C<<
9.
Supply pump pipe A


10.
Fuel return hose B

>>B<<
11.
Fuel return pipe

>>B<<
12.
Fuel injection pipe No.1
<<B>>
>>B<<
13.
Fuel injection pipe No.3

>>B<<
14.
Fuel injection pipe No.2
<<B>>
>>B<<
15.
Fuel injection pipe No.4

>>B<<
16.
Supply pump pipe B

>>B<<
17.
Common rail assembly

>>B<<
18.
Injector holder
<<C>>
>>B<<
19.
Fuel injector
<<D>>

20.
Nozzle gasket


21.
Common rail insulator


22
Suction control valve kit*

>>A<<
23.
Fuel supply pump assembly
note *: Unless replace, do not remove the suction control valve.

REMOVAL SERVICE POINTS



<<A>> HARNESS BRACKET REMOVAL



caution Too much pulling the harness bracket can possibly damage the insertion portion at the rocker cover side.

<<B>> FUEL INJECTION PIPE NO.3 / FUEL INJECTION PIPE NO.4 REMOVAL



Using the special tool fuel injection pipe wrench (MB992188), remove the fuel injector assembly side of fuel injection tube No. 3 and No. 4.

<<C>> FUEL INJECTOR REMOVAL


caution Always install the fuel injector to the cylinder from which the fuel injector was removed.

<<D>> NOZZLE GASKET REMOVAL



1.Insert the special tool Nozzle gasket remover (MB992333) into the fuel injector installation hole of the cylinder head.
2.As shown in the illustration, turn the tool dial. Hold the nozzle gasket and pull out the tool.

INSTALLATION SERVICE POINTS



>>A<< FUEL SUPPLY PUMP ASSEMBLY INSTALLATION


1.Install the O-ring to the fuel supply pump assembly.
note Make sure that it is free from dust nor cracks.
2.Install the fuel supply pump assembly to the cylinder head and the rear camshaft bearing cap.
note At that time, match the axis of the fuel supply pump assembly to the coupling shape.
3.After temporarily tightening the fuel supply pump assembly, tighten it gradually not once, but two or three times to the specified torque of 25 ± 7 N·m.

>>B<< FUEL RETURN PIPE / COMMON RAIL ASSEMBLY / FUEL INJECTION PIPE No.1 - No.4 / SUPPLY PUMP PIPE B / FUEL INJECTOR / INJECTOR HOLDER INSTALLATION





1.Follow the following procedures to clean the fuel injector (nozzle) and the cylinder head (fuel injector insertion hole).
(1)
caution Do not clean the nozzle spray hole.
Use the resin paddle and remove the carbon deposits from the fuel injector area "A" shown in the illustration.
(2) Carburettor cleaner (MZ100139) or the equivalent product to the injector spray hole.
(3)
caution Do not touch the nozzle spray hole by hand or wipe it by waste cloth.
Leave the injector spray hole for a while to melt the carbon deposits. And then blow air.
(4) Insert the special tool ornament remover (MB990784) into the cylinder head (fuel injector insertion hole). Remove carbon deposits.
(5)
caution Blow air at the piston top dead centre to prevent carbon deposits from increasing on the cylinder wall.
Remove the special tool MB990784. Blow air and remove carbon deposits from the cylinder head (fuel injector insertion hole).
(6) Check whether carbon deposits do not remain on the surface contacted with the fuel injector nozzle gasket.
note Repeat the procedures, from (4) to (6), until carbon deposits are thoroughly removed.
caution
  • The fuel injection pipe can be removed and reinstalled up to five times. To count how many times the fuel injection pipe is reinstalled, record the number of the reinstallation histories on the service booklet by adding this latest number, usually "1", to the previous one. Use a new injection pipe when the number of total reinstallation is five times, or when the injector or common rail assembly is replaced. In this case, record "New fuel injection pipe (number of total reinstallation: zero)" on the service booklet.
  • If a fuel leak is present in the fuel injection pipe and fuel injection pipe set 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 injection pipe set, 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.
  • Reinstall the fuel injection pipe, making sure that the seal surface is free of foreign materials and matching the pipe contact.



2.Temporarily install the fuel injector and the injector holder.
(1) Thoroughly remove foreign materials such as carbon deposits between the nozzle gasket and the cylinder head seating surface, also between the nozzle gasket and the injector.
(2) Apply oil to the tightening bolt threads of the injector holder, also to the flange reverse surface.
(3) Insert the injector holder into the fuel injector from the top. Turn the injector holder 90° and install it.
(4) Set the nozzle gasket to the installation location of the injector of the cylinder head.
note The nozzle gasket does not distinguish the front side from the reverse side. The oil application is not necessary.
(5) Insert the fuel injector into the installation location of the cylinder head.
note At that time, insert the fuel injector as perpendicularly as possible.
(6) Set the bolt and the washer to the injector holder. Place two bolts to the cylinder head seating surface at the same time and temporarily fix them. At that time, use the straight gauge and check whether the tilt of the injector holder is within 2 mm in the left and right directions.
(7) Check whether foreign materials or rust does not stay at the fuel feed threads of the fuel injector, also at the fuel return area and the high pressure pipe seating surface.
3.Temporary installation of common rail assembly
(1) Temporarily install the common rail assembly to the cylinder head with bolts. (The bolt slightly touches the common rail installation surface.)
note At that time, hold the rail body without holding the pressure limiter of the common rail assembly and the pressure sensor.
(2) Make sure the thread portion of the common rail assembly and the seat surface of the high pressure pipe are free of foreign materials or rust.
4.Temporarily install the fuel injection pipe No.1 to No.4. Temporarily install the supply pump pipe B and the fuel return pipe.
(1) Align the fuel injection pipe centre axis with the other side components (common rail assembly and fuel injector assembly) centre axis to install the fuel injection pipe No.1 to No.4.
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.
(2) Use bolts and temporarily fix the fuel return pipe to the rocker cover.
(3) Use flare nuts and temporarily fix the supply pump pipe B to the fuel injector and the common rail assembly.
note At that time, check the flare nuts at the pipe side smoothly rotate, and securely align the axis centres of the both pipe ends that contact each other.
(4) Use bolts and temporarily fix the clamp area of the supply pump pipe B to the rocker cover.


5.Install the fuel injector and the injector holder.
(1) Tighten the injector holder bolt (at the front engine side) to the tightening torque of 1.1 ± 0.1 N·m.
(2) As shown in the illustration, make a paint mark to the bolt top.
Based on the paint mark of the bolt, make the paint marks to the injector holder respectively: 90° in the direction of tightening the bolt on the engine front side and 180° in the direction of tightening the bolt on the rear engine side.
(3)
caution
  • When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
  • When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
Tighten the engine rear side bolt 180°. Check the paint mark of the injector holder and that of the bolt are aligned.
(4)
caution The tilt of the injector holder must be within 2 mm in the left and right directions. If the tilt is larger than the specified value, loosen the bolts and restart from the beginning.
Tighten the engine front side bolt 90°. Check the paint mark of the injector holder and that of the bolt are aligned.


6.Install the fuel injection pipe No.1 to No.4. Install the supply pump pipe B.
(1) Use the special tool crowfoot wrench (MB992211). To the temporary torque calculated by the following calculation formula, tighten the flare nuts of fuel injection tube set B at the common rail assembly side as well as the fuel injection tube No.1 to No.4.
Tightening torque: (18 ± 2) × {L ÷ (L + 25)} N·m

    18 ± 2: Tightening torque of the fuel injection tube (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)
(2) Using the special tool fuel injection pipe wrench (MB992188), tighten the fuel injector assembly side of fuel injection tube No. 3 and No. 4 and the supply pump side of fuel injection tube set B to the temporary tightening torque.
Tightening torque: 18 ± 2 N·m
(3) Use the special tool MB992211. To the specified torque calculated by the following calculation formula, tighten the flare nuts of fuel injection tube set B at the common rail assembly side as well as the fuel injection tube No.1 to No.4.
Tightening torque: (35 ± 5) × {L ÷ (L + 25)} N·m

    35 ± 5: Tightening torque of the fuel injection tube (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, tighten the fuel injector assembly side of the fuel injection tube No. 3 and No. 4 and the supply pump side of the fuel injection tube set B to the specified torque.
Tightening torque: 35 ± 5 N·m
(5) Tighten the clamp area of the supply pump pipe B to the specified torque of 11 ± 3 N·m.
7.Install the fuel return pump.
(1) Use the gasket and the eye bolt, and tighten the fuel return pipe together with the pressure limit of the common rail assembly to the specified torque of 20 ± 2 N·m.
(2) Tighten the fuel return pipe together with the rocker cover to the specified torque of 10 ± 2 N·m.
(3) Install the fuel return hose to the fuel return pipe with the hose clip.
8.Temporarily install the common rail assembly.
(1) To the specified torque of 25 ± 7 N·m, tighten the common rail assembly that is temporarily tightened.

>>C<< SUPPLY PUMP PIPE A INSTALLATION


1.Temporarily install the clamp of the supply pump pipe A to the rocker cover with bolts.

2.Use Special tool Fuel injection pipe wrench (MB992188) to install the supply pump pipe A.
3.Tighten the nuts of the supply pump pipe A to the temporary torque of 18 ± 2 N·m at the common rail side.

4.Use the special tool fuel injection pipe wrench (MB992211), Tighten the nuts of the supply pump pipe A at the common rail side to the temporary torque calculated by the following calculation formula.
Tightening torque: (18 ± 2) × {L ÷ (L + 25)} N·m

    18 ± 2: Tightening torque of the fuel injection tube (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)
5.Tighten the nuts of the supply pump pipe A at the fuel supply pump assembly side to the specified torque of 35 ± 5 N·m.
note Wrap around the fuel pipe with a seal tape to prevent the fuel pipe from being damaged.
6.Tighten the nuts of the supply pump pipe A at the common rail side to the specified torque calculated by the following calculation formula.
Tightening torque: (35 ± 5) × {L ÷ (L + 25)} N·m

    35 ± 5: Tightening torque of the fuel injection tube (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)
7.Tighten the clamp of the supply pump pipe A to the specified torque of 11 ± 3 N·m.

>>D<< FUEL PIPE INSTALLATION


1.Temporarily install the fuel pipe to the fuel supply pump assembly with bolt and washers.
2.Temporarily install the fuel pipe to the cylinder head with bolt.
3.Tighten the bolt to the specified torque of 17 ± 2 N·m at the fuel supply pump assembly side.
4.Tighten the cylinder head side bolt to the specified torque of 14 ± 3 N·m.
5.At the last, check the fuel does not leak from the connection portion of each pipe and from the gasket.