4.
Disconnect the fuel feed tube quick-connector (C).
Common Rail Fuel Injection System operates with extremely high pressure [approximately 1,800 bar (180 MPa / 26,106 psi)], so never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep cleanly the parts and the working area.
Pay attention to a foreign substance.
Just before installing injector, tube or hose, remove the protect-cap attached on them.
Do not remove injector except for special case.
When installing Injector
- Wash the contact area of the injector and replace the O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.
- Install the flange nut correctly.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
Disconnect the fuel pressure regulator valve connector (A).
Disconnect the fuel temperature sensor connector (B).
Disconnect the fuel feed tube quick-connector (C).
Remove the high pressure fuel pipe (A) connecting the high pressure fuel pump with the common rail.
Disconnect the return tube quick-connector (B) and the injector return hose (C).
High pressure fuel pipe installation nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 20.1 lb-ft)
Remove the oil gage guide.
Install the jack under the RH side of the engine.
Remove the engine mounting support bracket (A).
Tightening torque:
Nut (D) : 63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
Bolt (B), Nut (C) : 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
Remove the engine mounting insulator (B).
Remove the drive belt.
<a href="content.asp?vehicletype=Passenger&mfrcode=KM&area=KME&langcode=ENG&modelid=JD12&modelyr=2013&mmctype=en&mmcid=349&group=SHOP&pdftype=&cat1=2013+%3E+D+1%2E4+TCI%2DU2&ec=&firstnodedesc=Engine+Mechanical+System&sitinfolist=12%5E1205%5E12051110%5Enone%5E801%5E1%5EENG%5EKM%5EJD12%5E2013%5Een%5E348%5Enone%5Enone%5Enone%5ESHOP%5E%2412%5E1205%5E12051110%5Enone%5E801%5E4%5EENG%5EKM%5EJD12%5E2013%5Een%5E348%5Enone%5Enone%5Enone%5ESHOP%5E%24" target="_blank">(Refer to Engine Mechanical System - "Drive Belt")</a>
Turn the crankshaft pulley and align its groove with timing mark "T" of the timing chain cover.
(NO.1 cylinder compression TDC position.)
Remove the starter.
<a href="content.asp?vehicletype=Passenger&mfrcode=KM&area=KME&langcode=ENG&modelid=JD12&modelyr=2013&mmctype=en&mmcid=349&group=SHOP&pdftype=&cat1=2013+%3E+D+1%2E4+TCI%2DU2&ec=&firstnodedesc=Engine+Electrical+System&sitinfolist=11%5E1130%5E11300100%5Enone%5E801%5E1%5EENG%5EKM%5EJD12%5E2013%5Een%5E348%5Enone%5Enone%5Enone%5ESHOP%5E%2411%5E1130%5E11300100%5Enone%5E801%5E2%5EENG%5EKM%5EJD12%5E2013%5Een%5E348%5Enone%5Enone%5Enone%5ESHOP%5E%2411%5E1130%5E11300100%5Enone%5E801%5E4%5EENG%5EKM%5EJD12%5E2013%5Een%5E348%5Enone%5Enone%5Enone%5ESHOP%5E%2411%5E1130%5E11300100%5Enone%5E801%5E3%5EENG%5EKM%5EJD12%5E2013%5Een%5E348%5Enone%5Enone%5Enone%5ESHOP%5E%24" target="_blank">(Refer to Engine Electrical System - "Starter")</a>
Install the flywheel stopper (A) (SST No.: 09231-2B100) as below to keep the TDC position.
Remove the three high pressure fuel pump mounting bolts (A).
Tightening torque :
19.6 ~ 25.5 N.m (2.0 ~ 2.6 kgf.m, 14.5 ~ 18.8 lb-ft)
Remove the idler (A) and the timing chain cover plug (B).
Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
Install the high pressure fuel pump sprocket stopper (A).
(SST No.: 09331-2A010) with rotating it clockwise.
Lift the RH side of the engine with a jack.
Install the high pressure fuel pump remover (SST No.:09331-2A010) (A) with three mounting bolts (B).
Fix the high pressure fuel pump remover (SST No.:09331-2A010) (A) and sprocket stopper (C) with two fixing bolts (D).
Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:09331-2A010) (A) clockwise till the high pressure fuel pump is pushed out.
Installation is reverse of removal.
When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool (SST No.:09314-27120).
After removing or replacing the part below, bleed air in low pressure fuel circuit.
(Refer to Fuel Delivery System - "Bleeding Air in Low Pressure Fuel Circuit")
Fuel tank
Fuel sender
Fuel filter
High pressure fuel pump
Low pressure fuel lines
After removing or replacing fuel system below, must perform fuel leakage test procedure.
(Refer to Fuel Delivery System - "Fuel Leakage Test")
Fuel tank
Fuel sender
Fuel filter
High pressure fuel pump
Injector
Common rail
Low pressure fuel line
After replacing the High Pressure Pump, MUST perform the "ECU Initialization" procedure.
Otherwise trouble related with engine performance or emission control may occur until ECM learning about the component is over.
Turn ignition switch OFF.
Connect a GDS to Data Link Connector (DLC).
Turn ignition switch ON.
Select "Vehicle, Model year, Engine, System".
Select "Vehicle S/W Management".
Select "ECU Initialization".
Select "Pressure Pump Change".
Perform the procedure in accordance with the message.
