REMOVAL AND INSTALLATION


caution When the supply pump is replaced, perform the supply pump learning (Refer to GROUP 00 - Precautions before Service, What the Common Rail Engine Learns ).
Pre-removal Operation
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Engine Cover Removal (Refer to GROUP 11C - Engine Assembly ).
  • Vacuum Pump Removal (Refer to GROUP 11C - Vacuum Pump ).
  • Inlet Manifold Removal (Refer to GROUP 15 - Inlet Manifold ).

 Post-installation Operation
  • Inlet Manifold Installation (Refer to GROUP 15 - Inlet Manifold ).
  • Vacuum Pump Installation (Refer to GROUP 11C - Vacuum Pump ).
  • Engine Cover Installation (Refer to GROUP 11C - Engine Assembly ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • A/C Drive Belt Tension Check and Adjustment (Refer to GROUP 11C - On-Vehicle Service, Drive Belt Tension Check and Adjustment ).




Removal steps
<<A>>
·
 Set No.1 cylinder to TDC of its compression stroke (Removal only).
<<B>>
1.
 A/C drive belt


2.
 A/C compressor and clutch assembly connector connection
<<C>>
3.
 A/C compressor and clutch assembly


4.
 Compressor bracket assembly


5.
 Control wiring harness and crank/ cam position sensor wiring harness connection


6.
 Engine oil pressure switch connector connection


7.
 Suction control valve connector connection


8.
 Fuel temperature sensor connector connection


9.
 Control wiring harness


10.
 Harness bracket


11.
 Fuel hose connection


12.
 Fuel return hose connection
<<D>>
 >>B<<
 13.
 Engine oil pressure switch


14.
 Oil pipe assembly


15.
 Gasket


16.
 Supply pump holder bracket


17.
 Timing gear case stiffener

>>A<<
 18.
 Supply pump and supply pump holder assembly


19.
 Gasket

REMOVAL SERVICE POINTS

<<A>> SET NO.1 CYLINDER TO TDC OF ITS COMPRESSION STROKE.
caution Never turn the crankshaft anti-clockwise.


Turn the crankshaft clockwise, align each timing mark to set No.1 cylinder to TDC (top dead centre) of its compression stroke.
note When viewed from the front, the alignment mark on the supply pump gear deviates from that on the front plate by about 1 - 2 gears.

<<B>> A/C DRIVE BELT REMOVAL

1.Loosen the locking nut of the tension pulley.
2.
caution To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Rotate the adjusting bolt to the anti-clockwise direction (to the left), and remove the drive belt.

<<C>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1.With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2.After removing the A/C compressor and clutch assembly, secure it with a cord in the location where the removal and installation of the supply pump and supply pump holder assembly cannot be hindered.

<<D>> ENGINE OIL PRESSURE SWITCH REMOVAL

Using special tool oil pressure switch wrench (MB992118), removal the engine oil pressure switch.

INSTALLATION SERVICE POINTS

>>A<< SUPPLY PUMP AND SUPPLY PUMP HOLDER ASSEMBLY INSTALLATION
1.Turn the crankshaft clockwise to bring No. 1 cylinder to TDC of its compression stroke.

2.Install the front plate after mating marks on the supply pump gear and the supply pump holder so that the supply gear cannot be rotated. It’s installed in front plate so that supply pump gear doesn’t revolve together with a match mark of supply pump gear and supply pump holder.

3.A white paint is applied to the gears having the alignment mark of the supply pump gear. Confirm the white paint on the supply pump gear is aligned with the alignment mark of the front plate.
note When viewed from the front, the alignment mark on the supply pump gear deviates from that on the front plate by about 1 - 2 gears.

>>B<< ENGINE OIL PRESSURE SWITCH INSTALLATION

1.
caution Be careful not to block the oil passage with sealant.
When reusing the engine oil pressure switch, apply the specified sealant to the threads.
Specified sealant: ThreeBond 1215 or equivalent
note Install the engine oil pressure switch immediately after applying sealant.

2.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
Tighten the engine oil pressure switch to the specified torque, using special tool oil pressure switch wrench (MB992118).
Tightening torque: 19 ± 3 N·m