note | *: Unless replace, do not remove the suction control valve. |
REMOVAL SERVICE POINTS |
<<A>> HARNESS BRACKET REMOVAL |
|
<<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 |
|
<<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.
|
2.Install the fuel supply pump assembly to the cylinder head and the rear camshaft bearing
cap.
|
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)
(2) Carburettor cleaner (MZ100139) or the equivalent product to the injector spray hole. (3)
(4) Insert the special tool ornament remover (MB990784) into the cylinder head (fuel injector insertion hole). Remove carbon deposits. (5)
(6) Check whether carbon deposits do not remain on the surface contacted with the fuel injector nozzle gasket.
|
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.
(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.)
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.
(3) Use flare nuts and temporarily fix the supply pump pipe B to the fuel injector and the common rail assembly.
|
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)
(4)
|
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
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) 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
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) 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
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)
Tightening torque: (35 ± 5) × {L ÷ (L + 25)} 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) |
>>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. |