Contents: Removal ↳ Installation ↳
Special tool
 | Worldwide Diagnostic System (WDS) 418-F224 |
 | Hand Vacuum/Pressure Pump 23-036A (416-D001) |
General equipment: Engine vacuum cleaner.
| Name | Specification |
| Silicone gasket and sealant | WSE-M4G323-A4 |
| Gasket material | WSK-M2G348-A5 |
| Grease for nipple connection of high pressure fuel supply line TBD | TBD |
Removal
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.
WARNING: Do not carry out any repairs to the fuel injection system while the engine is running. Fuel pressure in the system can reach 1600 bar. Failure to follow these instructions may result in injury.
WARNING: Do not perform any repairs to the fuel injection system without verifying that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or below 30°C, whichever is greater. Failure to follow these instructions may result in personal injury.
WARNING: After stopping the engine, wait at least one minute before attempting any repairs to the fuel injection system. Failure to follow these instructions may result in injury.
CAUTION: Make sure that the service area where the vehicle is being worked on is as clean and dust-free as possible. Foreign matter from clutch, brake, machining or welding operations may contaminate the fuel system and cause subsequent malfunction.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Diesel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, absolute cleanliness is especially important when working with these components. Open holes or lines should always be plugged using suitable plugs.
CAUTION: Do not disassemble or clean the inside of the fuel pump, even with ultrasonic cleaning. Always install a new fuel pump if necessary.
1. Using the Datalogger function of the Worldwide Diagnostic System (WDS), check that the fuel pressure has dropped to zero and the fuel temperature has reached the outside temperature or a temperature below 30°C, whichever is greater.
2. Remove the timing belt. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.
3.
NOTE: The fuel pump pulley is sealed against the fuel pump sprocket.
Remove the fuel pump pulley.
4. Remove the fuel pump seal. Discard the seal as it is no longer needed.
5. Remove the high pressure fuel supply line support bracket.
6.
CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.
Cover the generator with a lint-free material to prevent contamination.
7.
CAUTION: Cover the fuel metering valve and fuel temperature sensor connectors to prevent contamination from cleaning fluid.
Clean the fuel pump, fuel rail, high-pressure fuel supply line and adjacent areas. For more information, refer to the Cleaning the Fuel Injection System Components chapter in this section.
8.
CAUTION: The high pressure fuel supply line must remain in contact with the fuel pump and fuel rail until all nipple connections have been disconnected and cleaned. Failure to follow this instruction may allow dirt to enter the fuel injection system.
Disconnect the high pressure fuel supply line and clamp from the fuel pump and fuel rail.
9.
CAUTION: The high pressure fuel supply line must remain in contact with the fuel pump and fuel rail until all nipple connections have been disconnected and cleaned. Failure to follow this instruction may allow dirt to enter the fuel injection system.
Using an engine vacuum cleaner, remove foreign material from the high pressure fuel supply line, fuel pump and fuel rail.
10. Remove the high pressure fuel supply line.
11. Using an engine vacuum cleaner, remove foreign material from the fuel pump and fuel rail.
12. Install plugs into the open threaded holes on the fuel pump and fuel rail.
13.
NOTE: Mark the orientation of the clamp to ensure it is installed in the exact same position.
Remove the clamp from the high pressure fuel supply line.
14. Discard the high pressure fuel supply line as it is no longer needed.
15. Disconnect the plug connectors of the fuel metering valve and the fuel temperature sensor.
16. Remove the fuel pump support bracket bolts.
17. Disconnect the fuel return line from the fuel pump to the fuel filter from the fuel return line diffuser. Refer to Section 310-00 for additional information. Install plugs on the fuel pump return line and the fuel return line diffuser.
18. Disconnect the fuel pump fuel supply line from the fuel pump. Refer to Section 310-00 for additional information. Install plugs on the fuel pump fuel supply line and the fuel pump.
19. Disconnect the fuel injector return line from the fuel return line diffuser. Install plugs on the fuel injector return line and the fuel return line diffuser.
20. Remove the fuel pump sprocket mounting bolts.
21.
NOTE: The fuel pump mounting bolts are accessible through the provided holes, but the mounting bolts cannot be completely removed.
Remove the fuel pump and protective screen. Discard the gasket as it is no longer needed.
22. Remove the protective screen from the fuel pump.
Installation
WARNING: Do not smoke or carry a lighted cigarette or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.
WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.
CAUTION: Make sure that the service area where the vehicle is being worked on is as clean and dust-free as possible. Foreign matter from clutch, brake, machining or welding operations may contaminate the fuel system and cause subsequent malfunction.
CAUTION: Always perform the cleaning procedure before performing any repairs to fuel injection system components. Failure to follow this instruction may result in dirt entering the fuel injection system.
CAUTION: Diesel injection equipment is manufactured to very precise tolerances and with very small clearances. Therefore, absolute cleanliness is especially important when working with these components. Open holes or lines should always be plugged using suitable plugs.
CAUTION: Do not disassemble or clean the inside of the fuel pump, even with ultrasonic cleaning. Always install a new fuel pump if necessary.
NOTE: Install a new fuel pump gasket.
NOTE: Install a new fuel pump seal.
NOTE: Install a new high pressure fuel supply line.
1. Align the hole in the fuel pump drive with the marked line on the fuel pump body.
2.
NOTE: To properly install the fuel pump, tighten the bolts evenly.
Install the fuel pump.
3. Install the fuel pump sprocket mounting bolts.
4. Install the new fuel pump seal. Tighten the bolts in the sequence shown
5. Remove the plugs and connect the fuel injector return line to the fuel return line diffuser. Discard the plugs as they are no longer needed.
6. Remove the plugs and connect the fuel pump feed line to the fuel pump. Discard the plugs as they are no longer needed.
7. Install the protective screen on the fuel pump (for clarity, the fuel pump is shown removed).
8. Connect the plug connectors of the fuel metering valve and the fuel temperature sensor.
9.
NOTE: Ensure that the clamp is installed in the same position as it was before removal.
Install the clamp on the high pressure fuel supply line.
10. Lubricate the threads of the high pressure fuel supply line nipple connections using clean grease.
11.
CAUTION: Protect the generator from contamination. Failure to follow this instruction may result in premature failure of the generator.
Cover the generator with a lint-free material to prevent contamination.
12.
CAUTION: Do not strike the ends of the high pressure fuel supply line. Failure to do so may result in damage to the ends of the fuel line and foreign material being introduced into the fuel injection system.
CAUTION: Remove the plugs from the high-pressure fuel supply line, fuel injector and fuel rail as late as possible. Failure to do so may result in dirt entering the fuel injection system.
NOTE: Do not tighten the high pressure fuel supply line nipple connections at this stage.
NOTE: Apply pressure to the high pressure fuel supply line to keep the fuel line nipple in contact with the fuel pump and fuel rail cones when connecting.
Install a new high pressure fuel supply line.
- 1. Connect the high pressure fuel supply line to the fuel rail.
- 2. Connect the high pressure fuel supply line to the fuel pump.
- Discard the plugs as they are no longer needed.
13. Tighten the fuel pump support bracket bolts (the high pressure fuel supply line is shown removed for clarity).
14.
CAUTION: The high pressure fuel line nipple tightening tool should be positioned on the top of the nipple joint as this is where most of the material is. Failure to follow this instruction may result in damage to the nipple joint.
Tighten the nipple connections of the high-pressure fuel supply lines.
- 1. Tighten the nipple connections of the high pressure fuel supply lines to the fuel rail.
- 2. Tighten the nipple connection of the high pressure fuel supply line to the fuel pump.
15. Install the high pressure fuel supply line bracket.
16.
CAUTION: Use a new piece of clear plastic tubing with the special tool.
Remove the plug from the fuel pump return fuel line connector and, using the special tool, prime the fuel pump until clean fuel flows into the vacuum pump reservoir.
- Discard the plugs as they are no longer needed.
17. Remove the special tool.
18. Connect the fuel return line from the fuel pump to the fuel filter.
19.
NOTE: Using silicone gasket and sealant, seal the fuel pump pulley to the fuel pump sprocket.
NOTE: Apply gasket material to the outer edge of the bolt holes in the fuel pump pulley.
Install the fuel pump pulley.
20. Remove the lint-free material from the generator.
21. Install a new timing belt. For additional information, refer to Section 303-01A / 303-01B / 303-01C / 303-01D / 303-01E.