Mitsubishi L200. Manual - part 39

COMMON RAIL AND SUPPLY PUMP

ENGINE OVERHAUL

11B-30

CAUTION

*1: Unless replaced, do not remove the sensor.

<Euro5>

AKB00324

10

11

12

13

7

14

15

1

20 ± 2 N·m

10 ± 2 N·m

24 ± 4 N·m

35 ± 5 N·m

35 ± 5 N·m

AB

24 ± 4 N·m

6

8

2

16

17

20 ± 2 N·m

10 ± 2 N·m

5

8.9 ± 1.9 N·m

9

20 ± 4 N·m

20

24 ± 3 N·m

3

24 ± 3 N·m

10 ± 2 N·m

4

24 ± 3 N·m

18

19

Removal steps 

1.

Fuel return hose

2.

Fuel inlet hose

>>

B

<< 3.

EGR cooler brackct assenbly "B"

>>

B

<< 4.

EGR cooler brackct assenbly "A"

>>

B

<< 5.

EGR cooler

6.

Suction control valve kit *1

>>

B

<< 7.

Supply pump

>>

B

<< 8.

Fuel supply pump pipe bracket

>>

A

<< 9.

Fuel supply pump pipe

>>

A

<< 10. Bracket

11. Fuel injection No.1 pipe

>>

A

<< 12. Fuel injection No.2 pipe

>>

A

<< 13. Fuel injection No.3 pipe

>>

A

<< 14. Fuel injection No.4 pipe

>>

A

<< 15. Common rail

>>

A

<< 16. Eye bolt (Cylinder head side)

>>

A

<< 17. Fuel return gasket

>>

A

<< 18. Eye bolt (Common rail side)

>>

A

<< 19. Fuel return gasket

>>

A

<< 20. Fuel return pipe

Removal steps (Continued)

COMMON RAIL AND SUPPLY PUMP

ENGINE OVERHAUL

11B-31

CAUTION

*1: Unless replaced, do not remove the sensor.

INSTALLATION SERVICE POINTS

>>A<< BRACKET / FUEL INJECTION PIPE / COM-
MON RAIL / EYE BOLT / FUEL RETURN GASKET / 
FUEL RETURN PIPE INSTALLATION

CAUTION

• The reinstallation histories of the removed 

injection pipe are up to five times. To count 
how many times the injection pipe is rein-
stalled, record the number of the reinstalla-
tion histories on the service booklet by 
adding this latest number of the histories, 
which is usually "1", to the previous one. Use 
a new injection pipe when the total reinstalla-
tion history numbers reach five times, or 
when the injector or common rail is replaced. 
In this case, record "a new injection pipe, the 
number of the reinstallation histories is zero" 
on the service booklet.

• If a fuel leak is present in the fuel injection 

pipe and fuel injection pipe set once, do not 
reuse it and replace with a new one.

• If the fuel injector assembly, common rail 

assembly or supply pump assembly is 
replaced, the contact surface (seal surface) 
between the fuel injection pipe and fuel injec-
tion pipe set, and the other side component is 
changed, do not reuse the fuel injection pipe 
and fuel supply pump pipe and replace with a 
new one.

• When the injection pipe is reinstalled, confirm 

there is no foreign material on the seal sur-
face or in the pipe and then install it not to 
deviate from the axis, fitting the seal surface.

AK500705

1. Temporarily tighten the fuel return pipe with bolts.

AK801174

Cylinder
port

Bracket

AB

Hatched

2. Slightly put the hatched area of the bracket to the 

cylinder port and tighten it to the specified torque 
of 20 

± 2 N⋅m. <Euro5>

3. Tighten to the specified torque of 20 

± 2 N⋅m the 

eye bolt and the fuel return gasket located at the 
cylinder head side.

4. Temporarily tighten the common rail with bolts, 

holding the common rail body.

AK500706

Common rail

AB

Pressure sensor

Pressure limiter

NOTE: At this time, do not hold the pressure lim-
iter or pressure sensor of the common rail.
NOTE: Before the installation, confirm there is 
neither foreign material nor a rust on the threads 
and the sealing surface of a high-pressure pipe.

5. 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.

AK600656

MB992188

AB

COMMON RAIL AND SUPPLY PUMP

ENGINE OVERHAUL

11B-32

6. Using special tool Fuel injection pipe wrench 

(MB992188), install injection pipe assembly No.1 
to No.4.
Tighten to the specified torque of 35 

± 5 N⋅m the 

flare nuts of the fuel injection pipe No.1 to No.4 at 
injector side.

AK600668

MB992188

AB

7. Using special tool Fuel injection pipe wrench 

(MB992188), install injection pipe assembly No.1 
to No.4.
Tighten to the specified torque of 35 

± 5 N⋅m the 

flare nuts of the fuel injection pipe No.1 to No.4 at 
common rail side.

8. Tighten the common rail to the specified torque of 

24 

± 4 N⋅m.

9. Tighten to the specified torque of 20 

± 2 N⋅m the 

eye bolt and the fuel return gasket located at the 
common rail side.

10.Tighten the fuel return pipe to the specified torque 

of 10 

± 2 N⋅m.

11.Tighten to the specified torque of 10 

± 2 N⋅m the 

bolts of the fuel injection pipe No.1 to No.4.

>>B<< EGR COOLER / EGR COOLER BRACKET / 
SUPPLY PUMP / FUEL SUPPLY PUMP PIPE / 
FUEL SUPPLY PUMP PIPE BRACKET 
INSTALLATION

CAUTION

• The reinstallation histories of the removed 

fuel supply pump pipe are up to five times. To 
count how many times the fuel supply pump 
pipe is reinstalled, record the number of the 
reinstallation histories on the service booklet 
by adding this latest number of the histories, 
which is usually "1", to the previous one. Use 
a new fuel supply pump pipe when the total 
reinstallation history numbers reach five 
times, or when the supply pump or common 
rail is replaced. In this case, record "a new 
fuel supply pump pipe, the number of the 
reinstallation histories is zero" on the service 
booklet.

• If a fuel leak is present in the fuel injection 

pipe and fuel injection pipe set once, do not 
reuse it and replace with a new one.

• If the fuel injector assembly, common rail 

assembly or supply pump assembly is 
replaced, the contact surface (seal surface) 
between the fuel injection pipe and fuel injec-
tion pipe set, and the other side component is 
changed, do not reuse the fuel injection pipe 
and fuel supply pump pipe and replace with a 
new one.

• When the fuel supply pump pipe is rein-

stalled, confirm there is no foreign material on 
the seal surface or in the pipe and then install 
it not to deviate from the axis, fitting the seal 
surface.

1. 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.

2. Temporarily tighten the supply pump with bolts.
3. Temporarily tighten the fuel supply pump pipe 

flare nuts.

4. Tighten to the specified torque of 35 

± 5 N⋅m the 

flare nuts of the fuel supply pump pipe together 
with the supply pump and common rail.

COMMON RAIL AND SUPPLY PUMP

ENGINE OVERHAUL

11B-33

5. Tighten the supply pump to the specified torque of 

24 

± 4 N⋅m.

AK801189AC

Tightened together 
with the fuel supply
pump pipe bracket

<Except Euro5>

AKB00339AB

Tightened together 
with the fuel supply
pump pipe bracket

<Euro5>

6. Tighten the EGR cooler to the specified torque of 

24 

± 3 N⋅m.

NOTE: The arrow position shown in the illustra-
tion is tightened together with the fuel supply 
pump pipe bracket.

AK801190AB

Bracket

Fuel supply pump pipe

7. Tighten the EGR cooler bracket to the specified 

torque of 24 

± 3 N⋅m.

8. Tighten to the specified torque of 10 

± 2 N⋅m the 

installation fuel supply pump pipe bolts together 
with the fuel supply pump pipe bracket.