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Using special tool Oil pressure switch socket wrench (MB992118), removal the oil pressure
switch.
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1.Using the special tool Supply pump gear stopper (MB992096), hold the fuel supply pump
gear and idler gear B.
2.Remove the hold the fuel supply pump gear nut and idler gear B bolt.
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3.Using the special tool Side bearing puller (MB990810), remove the fuel supply pump gear.
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1.Install the fuel return pipe assembly lightly with bolt onto the cylinder head by
hand.
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2.Install fuel return pipe assembly to the cylinder head with gasket, eye bolt to the
specified torque to 20.2 ± 2.4 N·m.
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3.A temporary tightening makes common rail assembly cylinder head.
| note |
At this time, do not hold the pressure limiter or pressure sensor of the common rail.
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| note |
Before the installation, confirm there is neither foreign material nor a rust on the threads
and the sealing surface of a high-pressure pipe.
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4.Temporarily tighten the fuel injection pipe assembly No.1 to No.4 with nuts.
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5.Temporarily tighten the fuel injection pipe clamp with bolts.
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6.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly
No.1 to No.4.
Tighten the fuel injection pipe assembly No.1 to No.4 to the specified torque of 35 ± 5
N·m at injector side.
7.Tighten the injection pipe clamp to the specified torque of 10 ± 2 N·m.
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8.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly
No.1 to No.4.
Tighten the fuel injection pipe assembly No.1 to No.4 to the specified to torque of 35 ± 5
N·m at common rail side.
| note |
When there is a fear that a bruise is put, wind sealing tape around the fuel pipe, to
prevent damage.
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9.Install fuel return pipe assembly to the common rail assembly with gasket, eye bolt
to the specified torque to 20.2 ± 2.4 N·m.
10.Tighten the common rail assembly to the specified torque of 24 ± 4 N·m.
11.Tighten the fuel injection pipe to the specified torque of 10 ± 2 N·m.
12.Tighten the fuel return pipe assembly to the specified torque of 24 ± 4 N·m.
13.Install fuel return hose to the fuel return pipe assembly with hose clip.
14.Tighten the fuel pipe bracket to the specified torque of 10 ± 2 N·m.
15.Tighten the fuel return pipe assembly to the specified torque of 10 ± 2 N·m.
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1.Using the special tool Supply pump gear stopper (MB992096), hold the fuel supply pump
gear and idler gear B.
2.Torque the fuel supply pump gear nut to the specified torque 64 ± 5 N·m.
3.Torque the idler gear B bolt to the specified torque 43 ± 2 N·m.
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1.Turn the crankshaft clockwise to bring No. 1 cylinder to the top dead centre position.
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2.Install the front plate after aligning the marks on the fuel supply pump gear and the
fuel supply pump holder so that the fuel supply gear cannot be rotated.
It’s installed in front plate so that fuel supply pump gear doesn’t
revolve together with a match mark of fuel supply pump gear and fuel supply pump holder.
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3.A white paint is applied to the gears having the alignment mark of the fuel supply pump
gear. Confirm the white paint on the fuel supply pump gear is aligned with the alignment mark
of the front plate.
| note |
When viewed from the front, the alignment mark on the fuel supply pump gear deviates from
that on the front plate by about 1 - 2 gears.
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| note |
Confirm three marks of the supply pump gear are visible from the installation hole of
the power steering pump.
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1.
| caution |
Be careful not to block the oil passage with sealant.
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When reusing the sensor, apply the specified sealant to the threads.
Specified sealant:
Three bond 1215, Three bond 1212D or exact equivalent
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2.Tighten the engine oil pressure switch together with the oil filter bracket to the specified
torque, using special tool Oil pressure switch socket wrench (MB992118).
Tightening torque: 19 ± 3 N·m
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