Mitsubishi L200. Manual — part 202

COMMON RAIL AND SUPPLY PUMP

DIESEL FUEL

13A-604

<Euro5>

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

>> >>

D

<< 1.

Injection pump sprocket

2.

Fuel return hose

3.

Fuel inline hose

<<

B

>> >>

C

<< 4.

Fuel supply pump pipe

>>

C

<< 5.

Supply pump assembly
Fuel injection pipe removal
steps

2.

Fuel return hose

3.

Fuel inline hose

<<

B

>> >>

B

<< 4.

Fuel supply pump pipe

<<

C

>> >>

B

<< 6.

Fuel injection pipe
Common rail assembly removal
steps

2.

Fuel return hose

3.

Fuel inline hose

<<

B

>> >>

C

<< 4.

Fuel supply pump pipe

<<

C

>> >>

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

Fuel injection pipe removal
steps (Continued)

AC805678

13

1

20 ± 2 N·m

3

2

5

8

10

N

12

11

9

N

20 ± 2 N·m

10 ± 2 N·m

10 ± 2 N·m

10 ± 2 N·m

10 ± 2 N·m

10 ± 2 N·m

35 ± 5 N·m

35 ± 5 N·m

24 ± 4 N·m

24 ± 4 N·m

64 ± 5 N·m

AB

6

6

N

4

35 ± 5
N·m

35 ± 5
N·m

35 ± 5 N·m

35 ± 5 N·m

10 ± 2 N·m

7

COMMON RAIL AND SUPPLY PUMP

DIESEL FUEL

13A-605

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.

<<C>> FUEL INJECTION PIPE REMOVAL

Using special tool fuel injection pipe wrench
(MB992188), remove the fuel injection pipe assem-
bly No.1 to No.4.

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

>> >>

D

<< 1.

Injection pump sprocket

2.

Fuel return hose

3.

Fuel inline hose

<<

B

>> >>

C

<< 4.

Fuel supply pump pipe

>>

C

<< 5.

Supply pump assembly
Fuel injection pipe removal
steps

2.

Fuel return hose

3.

Fuel inline hose

<<

B

>> >>

B

<< 4.

Fuel supply pump pipe

<<

C

>> >>

B

<< 6.

Fuel injection pipe
Common rail assembly removal
steps

2.

Fuel return hose

3.

Fuel inline hose

<<

B

>> >>

C

<< 4.

Fuel supply pump pipe

<<

C

>> >>

A

<< 6.

Fuel injection pipe

7.

Fuel injection pipe bracket

>>

A

<< 8.

Eye bolt

>>

A

<< 9.

Fuel return gasket

>>

A

<< 10. Common rail assembly

>>

A

<< 11. Eye bolt

>>

A

<< 12. Fuel return gasket

>>

A

<< 13. Fuel return pipe

AC503013 AB

MB992048

Injection pump
sprocket

AC502178

AB

MB992098

Injection pump
sprocket

MB992099

AC901507AB

MB992188

COMMON RAIL AND SUPPLY PUMP

DIESEL FUEL

13A-606

INSTALLATION SERVICE POINTS

>>A<< FUEL RETURN PIPE/FUEL RETURN GAS-
KET/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:

17

± 2 N⋅m <Except Euro5>

20

± 2 N⋅m <Euro5>

CAUTION

• When operating, do not support the common

rail assembly by holding the rail pressure lim-
iter 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.

3. Temporarily tighten the common rail assembly

with bolts, holding the common rail assembly.

4. Align the fuel injection pipe centre axis with the

other side components (fuel injector assembly
and common rail assembly) centre axis to install
the fuel injection pipe. Then, tighten the flare nut
temporarily until the tip of pipe (seal surface)
contacts with the other side components.
NOTE: When the fuel injection pipe is installed,
tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.

5. Using special tool fuel injection pipe wrench

(MB992188), start tightening the fuel injector
assembly side flare nut in the fuel injection pipe,
and then tighten the fuel injector assembly side
flare nut and common rail assembly side flare nut
alternately in several steps to the specified torque.

Tightening torque: 35

± 5 N⋅m

6. Tighten the common rail assembly to the specified

torque.

Tightening torque: 24

± 4 N⋅m

7. 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

8. Tighten the fuel return pipe to the specified

torque.

Tightening torque: 10

± 2 N⋅m

9. Tighten the bolts of the fuel injection pipe to the

specified torque.

Tightening torque: 10

± 2 N⋅m

10.Tighten the common rail assembly side flare nut

in the fuel supply pump pipe and the supply pump
assembly side flare nut alternately in several
steps to the specified torque.

Tightening torque: 35

± 5 N⋅m

AC502866AB

Fuel return pipe

Common rail
assembly

AC502867AB

Pressure limiter

Common rail

Pressure
sensor

AK600656

MB992188

AB

AK600668

MB992188

AB

COMMON RAIL AND SUPPLY PUMP

DIESEL FUEL

13A-607

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

CAUTION

• When operating, do not support the common

rail assembly by holding the rail pressure lim-
iter 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.

1. Loosen the common rail assembly mounting bolts

so that the common rail assembly will be in the
temporarily installed state.

2. Align the fuel injection pipe centre axis with the

other side components (fuel injector assembly
and common rail assembly) centre axis to install
the fuel injection pipe. Then, tighten the flare nut
temporarily until the tip of pipe (seal surface)
contacts with the other side components.
NOTE: When the fuel injection pipe is installed,
tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.

3. Using special tool fuel injection pipe wrench

(MB992188), start tightening the fuel injector
assembly side flare nut in the fuel injection pipe,
and then tighten the fuel injector assembly side
flare nut and common rail assembly side flare nut
alternately in several steps to the specified torque.

Tightening torque: 35

± 5 N⋅m

4. Tighten the common rail assembly to the specified

torque.

Tightening torque: 24

± 4 N⋅m

5. Tighten the common rail assembly side flare nut in

the fuel supply pump pipe and the supply pump
assembly side flare nut alternately in several
steps to the specified torque.

Tightening torque: 35

± 5 N⋅m

>>C<< SUPPLY PUMP ASSEMBLY/FUEL SUPPLY
PUMP PIPE INSTALLATION
1. Temporarily tighten the supply pump assembly

with bolts.

2. Align the fuel supply pump pipe centre axis with

the other side components (common rail
assembly and supply pump assembly) centre axis
to install the fuel supply pump pipe. Then, tighten
the flare nut temporarily until the tip of pipe (seal
surface) contacts with the other side components.
NOTE: When the fuel supply pump pipe is
installed, tighten the flare nut while shaking the
pipe lightly to align the centre axis of both compo-
nents.

AC502867AB

Pressure limiter

Common rail

Pressure
sensor

AK600656

MB992188

AB

AK600668

MB992188

AB