FUEL INJECTION (FUEL SYSTEMS)(H4DOTC DIESEL) > Fuel Pump

INSTALLATION

CAUTION:

When installing the fuel pump, always replace the fuel delivery pipes between the fuel pump and common rail assembly with new parts.

1. Loosen the bolts on the common rail assembly.

2. Loosen the bolts of fuel pipe holder (A) and fuel pipe holder stay (B).

3. Install the fuel pump.

NOTE:

Use new O-rings.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

4. Temporarily tighten the fuel delivery pipes.

5. Tighten the fuel pipe holder stay bolts.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

6. Tighten the common rail assembly bolts.

NOTE:

Start tightening from the bolt on the common rail pressure sensor side.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

7. Tighten the fuel delivery pipe nuts between the fuel pump and common rail assembly.

CAUTION:

Be careful not to apply an unbalanced load when tightening.

NOTE:

Perform the work while fixing the holder (A) in figure below with a spanner.

Tightening torque:

35 N·m (3.6 kgf-m, 25.8 ft-lb)

8. Tighten the fuel pipe holder bolts.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

9. Install the fuel pipe.

NOTE:

Use a new gasket.

Tightening torque:

T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T2: 17 N·m (1.7 kgf-m, 12.5 ft-lb)

LHD model

RHD model

10. Install the fuel return pipes.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

LHD model

RHD model

11. Connect the harness connectors to the suction control valve and fuel temperature sensor, and connect the harness clip to the pipe.

12. Install the fuel pump gear.

13. Install the chain cover.

14. Install the intake manifold.

15. For the remaining parts, install in the reverse order of removal.

16. Pump the priming pump on top of the fuel filter assembly to fill the fuel system with fuel.

NOTE:

Pump the priming pump until it is stiff.

17. If the fuel pump is replaced, perform compulsory learning mode.

18. Check for fuel leakage.