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
  • Reduce Pressurized Fuel Lines (Refer to ).
  • Engine Upper Cover Removal (Refer to ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).

Post-installation Operation
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Fuel Line Leak Check (Refer to )
  • Engine Upper Cover Installation (Refer to ).





Removal steps
<<A>>
>>A<<
1.
Fuel injection pipe set A
<<A>>
>>A<<
2.
Fuel injection pipe set B


3.
Fuel return line hose B


4.
Suction control valve connector


5.
Fuel temperature sensor connector


6.
Fuel return line hose A


7.
Fuel main hose connection


8.
Fuel return hose connection


9.
Fuel line pipe assembly


10.
Gasket


11.
Harness bracket


12.
Supply pump assembly


13.
O-ring

REMOVAL SERVICE POINT



<<A>> FUEL INJECTION PIPE SET A/FUEL INJECTION PIPE SET B REMOVAL



Using the special tool fuel injection pipe wrench (MB992188), remove the supply pump side of fuel injection pipe set A and B.

INSTALLATION SERVICE POINT



>>A<< FUEL INJECTION TUBE SET B/FUEL INJECTION TUBE SET A INSTALLATION


1.
caution
  • The removed fuel injection pipe can be reassembled up to five times. To count the number of fuel injection 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 fuel injector assembly or common rail assembly is replaced, always use a new fuel injection pipe. At that time, write "New (0 times)" in the maintenance handbook.
  • 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.
  • When reassembling the fuel injection pipe, remove the foreign material attached on the sealing surface, and install it with the contacting point of the pipe aligned.
Align the fuel injection pipe centre axis with the other side components (common rail assembly and supply pump 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.

2.Using the special tool fuel injection pipe wrench (MB992188), tighten the supply pump side of fuel injection pipe set A and B 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 fuel injection pipe set A 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, tighten the supply pump side of the fuel injection pipe set A and B to the specified torque.
Tightening torque: 35 ± 5 N·m
5.Using the special tool MB992211, tighten the common rail assembly side of the fuel injection pipe set A 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 fuel injection pipe connection area.