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Foreword
This manual describes the procedures for assembling and disassembling the supply pump
(HP3) for the common rail type electronically controlled fuel injection system. Also, the proce-
dures below are explained using a 294000-001# as a reference. If working on a different model
of pump, be sure to verify the component parts against the parts list before beginning.
Please read the contents thoroughly and apply them carefully in your service and maintenance
work.
To ensure a safe operation, this manual indicates the particulars that must be adhered to in the
following manner:
WARNING
• Be careful with any fuel or oil leaks, as they could cause a fire.
• Be careful with hot fuel, as it could cause burns.
• The fuel in the fuel pipe reaches an extremely high pressure. Therefore gradually reduce the fuel pres-
sure (to atmospheric pressure) before disconnecting parts or high pressure pipes during a test.
NOTE
• Foreign particles such as dust or debris (less than 0.1mm) in the supply pump can cause a malfunc-
tion, so please observe the following:
[1] Avoid bringing foreign particles into the work area by thoroughly cleaning any dust or debris
on the outside of any pump to be repaired before overhauling it.
[2] The workbench should be covered with unpainted stainless steel.
[3] The workbench and all tools should be vacuum cleaned before overhauling.
[4] All parts, including new ones, should be cleaned with clean diesel fuel before installation.
If exposed for long periods after cleaning, dust may accumulate so parts should be installed
immediately after cleaning. Also, when cleaning parts in the punching metal case, carry the
entire case back to the work area and do not leave it on the workbench.
If punching metal is not used in the parts case, foreign particles could be left in the case.
[5] Always wash your hands before disassem-
bling and reassembling a pump.
• Do not reuse O-rings and gaskets.
• Always use the appropriate tools.
• Always apply proper tightening torque to parts.
• Do not carry a pump by the pipe as shown at right.
WARNING
Failure to adhere to the precautions could cause accidents, which could lead to
serious injury or death.
NOTE
Failure to adhere to the precautions could cause accidents, injury, or damage to
the vehicle or product.
ADVICE
Gives reference information regarding the operation.
Items marked like this must not be done.
QD0952
