REMOVAL AND INSTALLATION







Removal steps


1.
Fuel return hose


2.
Fuel inlet hose

>>B<<
3.
Supply pump

>>B<<
4.
Fuel supply pump pipe bracket

>>B<<
5.
Fuel supply pump pipe

>>A<<
6.
Fuel injection No.1 pipe

>>A<<
7.
Fuel injection No.2 pipe

>>A<<
8.
Fuel injection No.3 pipe

>>A<<
9.
Fuel injection No.4 pipe

>>A<<
10.
Common rail

>>A<<
11.
Eye bolt (Cylinder head side)

>>A<<
12.
Fuel return gasket

>>A<<
13.
Eye bolt (Common rail side)

>>A<<
14.
Fuel return gasket

>>A<<
15.
Fuel return pipe

INSTALLATION SERVICE POINTS



>>A<< FUEL INJECTION PIPE / COMMON RAIL / EYE BOLT / FUEL RETURN GASKET / FUEL RETURN PIPE INSTALLATION


caution
  • The reinstallation histories of the removed injection pipe are up to five times. To count how many times the injection pipe is 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 injection pipe when the total reinstallation history numbers reach five times, or when the injector or common rail is replaced. In this case, record "a new injection pipe, the number of the reinstallation histories is zero" on the service booklet.

  • 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.

1.Temporarily tighten the fuel return pipe with bolts.
2.Tighten to the specified torque of 20 ± 2 N·m the eye bolt and the fuel return gasket located at the cylinder head side.

3.Temporarily tighten the common rail with bolts, holding the common rail body.
note At this time, do not hold the pressure limiter or pressure sensor of the common rail.
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.

4.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly No.1 to No.4.
Tighten to the specified torque of 35 ± 5 N·m the flare nuts of the fuel injection pipe No.1 to No.4 at injector side.

5.Using special tool Fuel injection pipe wrench (MB992188), install injection pipe assembly No.1 to No.4.
Tighten to the specified torque of 35 ± 5 N·m the flare nuts of the fuel injection pipe No.1 to No.4 at common rail side.
6.Tighten the common rail to the specified torque of 24 ± 4 N·m.
7.Tighten to the specified torque of 20 ± 2 N·m the eye bolt and the fuel return gasket located at the common rail side.
8.Tighten the fuel return pipe to the specified torque of 10 ± 2 N·m.
9.Tighten to the specified torque of 10 ± 2 N·m the bolts of the fuel injection pipe No.1 to No.4.

>>B<< SUPPLY PUMP / FUEL SUPPLY PUMP PIPE INSTALLATION


caution
  • The reinstallation histories of the removed supply pump pipe are up to five times. To count how many times the supply pump pipe is 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 supply pump pipe when the total reinstallation history numbers reach five times, or when the supply pump or common rail is replaced. In this case, record "a new supply pump pipe, the number of the reinstallation histories is zero" on the service booklet.

  • When the supply pump 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.
1.Temporarily tighten the supply pump with bolts.
2.Tighten to the specified torque of 35 ± 5 N·m the flare nuts of the supply pipe together with the supply pump and common rail.
3.Tighten the supply pump to the specified torque of 24 ± 4 N·m.
4.Tighten to the specified torque of 24 ± 4 N·m the installation supply pipe bolts together with the supply pump pipe bracket.