REMOVAL AND 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 injector 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.

Pre-removal Operation

Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
Throttle Body Removal (Refer to ).
EGR Valve and EGR Cooler Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
Inlet Manifold Removal (Refer to GROUP 15 - Inlet Manifold ).

Post-installation Operation

Inlet Manifold Installation (Refer to GROUP 15 - Inlet Manifold ).
EGR Valve and EGR Cooler Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
Throttle Body Installation (Refer to ).
Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
Air Bleeding from Fuel Line (Refer to ).

			Supply pump assembly removal steps
		·	When the supply pump assembly is replaced, perform the supply pump learning.(Refer to GROUP 00 - Precautions before Service, What the Common Rail Engine Learns ) <Installation only>.
		·	Timing belt (Refer to GROUP 11A - Timing belt ).
<<A>>	>>C<<	1.	Injection pump sprocket
		2.	Fuel return hose
		3.	Fuel inline hose
<<B>>	>>B<<	4.	Fuel supply pump pipe
	>>B<<	5.	Supply pump assembly
			Fuel injection pipe and common rail assembly removal steps
		2.	Fuel return hose
		3.	Fuel inline hose
<<B>>	>>B<<	4.	Fuel supply pump pipe
	>>A<<	6.	Fuel injection pipe
	>>A<<	7.	Eye bolt
	>>A<<	8.	Fuel return gasket
	>>A<<	9.	Common rail assembly
	>>A<<	10.	Eye bolt
	>>A<<	11.	Fuel return gasket
	>>A<<	12.	Fuel return pipe

REMOVAL SERVICE POINTS

<<A>> INJECTION PUMP SPROCKET REMOVAL

1.Using special tool sprocket holder (MB992048), lock the injection pump sprocket, and then loosen the injection pump sprocket mounting nut.

2.Using the special tools below, remove the injection pump sprocket.

Injection pump sprocket puller (MB992098)
Crank pulley puller (MB992099)

<<B>> FUEL SUPPLY PUMP PIPE REMOVAL

caution

When removing the fuel supply pump pipe, the fuel pressure in the fuel line is high. Thus, wait for 3 minutes or longer after the engine stops, and cover the fuel supply pump pipe with a rag or similar materials to prevent the fuel splash, and then disconnect the fuel supply pump pipe.

INSTALLATION SERVICE POINTS

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

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

caution

When operating, do not support the common rail assembly by holding the rail pressure limiter and the pressure sensor at both ends.
Before the installation, make sure that there is no foreign object or rust to the thread and to the high-pressure pipe sheet surface.

Temporarily tighten the common rail assembly with bolts, holding the common rail assembly.
4.Temporarily tighten the fuel injection pipes.
5.Tighten the flare nuts of the fuel injection pipe located at the fuel injector side to the specified torque.
Tightening torque: 35 ± 5 N·m
6.Tighten the flare nuts of the fuel injection pipe located at the common rail assembly side to the specified torque.
Tightening torque: 35 ± 5 N·m
7.Tighten the common rail assembly to the specified torque.
Tightening torque: 24 ± 4 N·m
8.Tighten the eye bolt and the fuel return gasket located at the common rail assembly side to the specified torque.
Tightening torque: 20 ± 2 N·m
9.Tighten the fuel return pipe to the specified torque.
Tightening torque: 10 ± 2 N·m
10.Tighten the bolts of the fuel injection pipe to the specified torque.
Tightening torque: 10 ± 2 N·m

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

1.Temporarily tighten the supply pump assembly with bolts.

2.Tighten the flare nuts of the fuel supply pump pipe together with the supply pump assembly and common rail assembly to the specified torque.
Tightening torque: 35 ± 5 N·m

3.Tighten the supply pump assembly bolts to the specified torque.
Tightening torque: 24 ± 4 N·m

4.Tighten the fuel supply pump pipe bolt.

>>C<< INJECTION PUMP SPROCKET INSTALLATION

In the same manner as for removal, using special tool sprocket holder (MB992048), lock the injection pump sprocket, and then tighten the injection pump sprocket mounting nut to the specified torque.
Tightening torque: 64 ± 5 N·m