CRI-EnG06.2 DisassyAssy FuelPump

Technical Presentation Kit
SAA6DF140/125--CRI
SAA6DF140/125 Engines
Disassembly & Assembly

Fuel Pump
Section 6.2
SAA6D140/125-CRI
SAA6D140/125-
KT900201
February 2001 Menu Exit
SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

02/00
Page 6-
6-2
Parts of CRI supply pump
KT900201 - Disassembly & Assembly Menu Exit

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-3
Tools for BENCH Test

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

02/00
Page 6-
6-4
1) Attach STAND on a
vise
2) Attach PUMP with four

sockets bolts (M8, M10)
on the STAND

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-5
Remove ELEMENT Assembly

Using puller bolts and install
PCV PULLER 95092-11560
Tighten PCV PULLER bolts evenly

and remove ELEMENT.
(Socket wrench set)
Note: lift upward horizontally to
prevent any damage

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-6
Picking up the
PLUNGER remained in
the HOUSING with
PINSET hand carefully
to prevent any damage.
Mark the No.1

Element & Plunger to
do not mix with parts
from No.2

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-7
Removal of PCV
Attach PCV MOUNTING
(95092-11250) on the
vise and Attach the
ELEMENT on the PCV
MOUNTING

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-8
Remove PCV by 42 mm
SOCKET WRENCH.
Use extension bar (Approx. 50cm
Remove STOPPER with

PINSET magnetic bar.
Not re-usable, Replace
STOPPER every time

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-9
Loosen vice and change mounting

angle.
Remove VALVE HOLDER

with a deep 22mm socket

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-10
Remove VALVE, SPRING,

DELIVERY VALVE & DELIVER
VALVE HOLDER with flexible
magnetic tool
Remove WASHER
(Copper).
Not re-useable
DO NOT MIX THE
PARTS ON No.1 & No.2
PCV.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-11
Removal of UPPER SPRING

SEAT
•Attach HOLDING SPANNER
by the shaft and key.
•Turn the shaft to lower dead
point of the cam position
where UPPER SPRING CLIP
can be removed.
•Remove HOLDING
SPANNER and key from the
pump.
Be careful to rotating shaft
when UPPER SPRING is
removed.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-12
•Attach the UPPER

SPRING SEAT
EXTRACTOR on the
pump.
•Insert pin of HOLDER in
half circle groove and
keeping pressed, turn
handle with 90 degree to
remove UPPER
SPRING SEAT.
Note: Do not press with

excessive for which may
cause damage by lower part
of SEAT.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-13
Remove SPRING,
LOWER SPRING and
TAPPET with PINSET
Flexible magnetic tool.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-14
Drain LUB OIL from pump housing

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-15
Removal of FEED
PUMP
Remove pump cover
and O-ring.
Push PRIMMING
PUMP to drain
remaining fuel after
cover removed.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-16
Remove SIDE PLATE (outer)

loosening 4 bolts.
Remove CASING with

FEED PUMP PLIER.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-17
Remove OUTER ROTOR5)

Remove INNER ROTOR and
key.
Inlet
Outlet
Wider is low.
Remove SIDE PLATE

(inner).

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-18
Removal of FEED PUMP
1) Remove FEED PUMP housing from SUPPLY PUMP

loosening bolts.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-19
Removal of G sensor.
1) Remove FEED PUMP housing from SUPPLY

PUMP loosening bolts.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-20
Removal of camshaft
Remove bearing cover.
( 5mm wrench )
2) Remove the bolts for

BEARING COVER. And
Press shaft assembly to
remove from housing.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-21
Remove BEARING
COVER and Shims.
Remove camshaft
carefully to prevent
any damage

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-22
Remove BEARING and OUTER

RACE
1) Set BEARING PULLER (95720-

00070), HOOKSET (95092-11070),
BASE (95092-11260) and put
BEARING COVER on BASE.
Remove OUTER
RACE with hand
press

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-23
Removal of OIL SEAL
1) Remove OIL SEAL with hand press using REPLACER

and HANDLE.
34mm

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-24
Removal of WEAR RING
Place SHAFT Assembly in a vise.

Strike WEAR RING with hammer.
Remove WEAR RING from camshaft

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-25
Removal of BEARING and

ROLLER
1) Fix camshaft with SUPPORT
and remove two (2) bearings by
hand press.
Use CAP to screw to prevent

any damage, when press
KT900201 - Disassembly & Assembly
shaft.
shaft. Menu Exit
SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-26
12. Removal of oil seal

1) Put oil seal on the
stepped area on
REPLACER and install it.
95092-11550 to be abolished
95720-00070 to be used
2) Press in SPACER
and fix it with PIN.
Push out oil seal remover.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-27
Removal of BEARING
OUTER RACE
1) Put the HOUSING on

the BASE and remove it
with REPLACER and
hand press.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-28
Assembling
Assembling of
BEARING OUTER
RACE
Use the BASE as a
guide, put BEARING
OUTER RACE and
remove BASE.
Note: Apply gear oil on the
outer surface of the BEARING
OUTER RACE.
TOOL: BASE
95092-11460 ∅62 6HD
95092-11470 ∅72 6UHD

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-29
Put REPLACER on the

OUTER RACE whose
BASE is removed, and
presses in till the end
of REPLACER (as
shown in the Fig.)
REPLACER: 95092-
11400 (∅81)
Note: After installation of feed pump case, push OUTER

RACE back to end of case. (Approx. 0.5mm)
SAA6D140/125--CRI
SAA6D140/125
Fuel Pump Assembly TPK

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Page 6-
6-30
Installation of OIL SEAL

Set OIL SEAL GUIDE and
insert OIL SEAL and press
in with hand press. (Lock-
Tight)
Apply gear oil on the

outer surface of OIL
SEAL.

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-31
4) To prepare TOOL for

pressing combining BEARNG
OUTER RACE of FEED
PUMP, 2 kinds of
REPLACER, handle and
adapter.
Press in till end of PUMP
housing by hand press.
REPLACER:95092-
11360(∅52)(6HD)
95092-
11370(∅60)(6UHD)
95092-11360(∅61)(6HD)
95092-11360(∅71)(6UHD) Note: Press OUTER RACE
Handle 09951-11300 back to end of case. (Approx.
Adapter 95092-11310 0.5mm)
SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-32
Installation of BEARING
ROLLER
Press in ROLLER of drive
side BEARING.
Press in BEARING of FEED
PUMP.
Pipe (∅30) :95092-11480
Note: Apply gear oil when

pressing in.

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-33
Installation of BEARING COVER

Press BEARING OUTER RACE into
BEARING COVER.
REPRACER:95092-11360(∅52)(6HD)
:95092-11370(∅60)(6UHD)
:95092-11360(∅61)(6HD)
:95092-11360(∅71)(6UHD)
HNDLE :09951-11300
ADAPTER :95092-11310
Note: Apply gear oil when pressing in
BEARING OUTER RACE.

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-34
Installation of PCV
Put a new STOPPER
with PINSET
Note: See the RH figure.
2) Install a new O-ring on
ELEMENT and apply
grease

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-35
)Install PCV on ELEMENT fixed

on the PCV MOUNTING.
Torque: 167+ -10Nm(17+ -1Kgf･m)
Note: Using a torque wrench with

limiter and tight it fully with out
stopping.
.Installation of
DELIVERY VALVE
After changing gasket and O-
ring with new ones, apply
grease to O-ring and thread of
DELIVERY VALVE HOLDER
and assemble them with hand.
SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-36
After changing fixing angle, tight it

with DEEP SOCKET.
Torque :152+ -15Nm(15.5+ -1.5Kgfm)
Note: Use torque wrench

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-37
.Installation of CAMSHAFT and BEARING

COVER
)After installing CAMSHAFT into PUMP
HOOSING, install GUIDE PIN and BEARING
COVER without O-ring.
GUIDE PIN: 95092-11510
Note: Insert CAMSHAFT carefully preventing from
damage on OIL SEAL of the PUMP.
Note: When install BEARING COVER, do not

damage OIL SEAL of FEED Pump.
)Using HAND PRESS, press in

BEARING COVER and then tighter bolts.
Pipe: 95092-11480
SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-38
.Measurement of CAMSHAFT
clearance
)Install GUIDE RALL on the end
of CAMSHAFT and measure
radial protrusion of the
CAMSHAFT.
When out of criteria, change
thickness of ADJUSTING SHIM.
Torque of BEARING COVER
BOLT
: 8.8+ -2.0Nm(0.9+ -0.2Kgfm)
GUIDE RAIL: 95092-10710(∅25)(6HD,
6UHD)
NUT: 95092-20210
Protrusion criteria：16.5+ -0.3mm (6HD)

13.5+ -0.3mm (6UHD)

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-39
)Install CAMSHAFT clearance

MEASURE to CAMSHAFT and
measure clearance.
clearance criteria: 0.03+ -0.03mm
CAMSHAFT clearance MEASURE:

95092-11180(∅25) (6HD)
95092-11180(∅φ30) (6UHD)
Note: When out of criteria, change thickness

of ADJUSTING SHIM. When within criteria,
apply grease to O-ring and install BEARNG
COVER. And measure clearance again
Need to review the clearance measure.

Change to rotating torque of camshaft
measuring.

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-40
9. Installation of G SENSOR
1) Insert MASTER, an attachment
of
SENSOR MEASUREMENT.
SENSOR MEASURE 95092-11540
2) Set a dial gauge in “o”, zero

keeping MASTER pressed down
firmly in SENSOR MEASURE.
3) Insert G SENSOR firmly and
read indicated value (L1) on the dial
gauge

SAA6D140/125--CRI
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Page 6-
6-41
Remarks: There is 0.4 mm difference

between two kinds of MASTER, which are
used at measurement.
Air gap criteria
0.42 0.05mm(6HD)
0.82 0.05mm(6UHD)
HD: 0.395 – 0.42mm
UHD: 0.795 – 0.815mm

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-42
5) Read difference (L2)

between
MASTER and calculate and
select shim thickness (t) to
adjust air gap distance from
installation surface of G
SENSOR to the PULSER on
the CAMSHAFT.
t =L1-L2
t=L1-L2+0.4
4) Keep DEOTH MEASURE
pressed firmly to MASTER
and set the dial gauge in “O”
zero
MEASURE DEPTH: 95092-
11530
SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-43
6) Apply grease to O-ring and install G

SENSOR with selected shim.
To tightening torque: 6.37+ -1.97Nm
(0.65+ -0.20Kgfm)

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-44
10. Installation of TAPPET

1) Insert TAPPET slowly into
PUMP HOUSING.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

02/00
Page 6-
6-45
2) Insert LOWER SPRING SEAT

3) Install PLUNGER SPRING

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-46
11. Install UPPER SPRING

SEAT
1) Using EXTRACTOR,
match the insert position of
UPPER SPING SEAT and
turn 90 degree to fix it during
keeping pressed down
firmly.
Note: Be careful not to push
down
EXTRACTOR with
excessive force to prevent
from cutting Housing by seat
EXTRACTOR HOLDER
Ass’y
SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

02/00
Page 6-
6-47
12. TROCHOID type

1) Install SIDE PLATE
(inner).
Put narrow groove side to
lower.
2) Install INNER ROTOR
Make sure INNER ROTOR
to enter smoothly.
3) Install CASING
Make sure installation
direction.
4) Install OUTER ROTOR.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

02/00
Page 6-
6-48
5) Make sure holes position

of suction and outlet, install
SIDE PLATE (OUTER) and
tighter 4 screws to fix it.
Tightening torque 2.45+ -
0.49Nm(0.25+ -0.05Kgfm)
6) Apply grease to O-ring
and install it.
7) Put COVER and fix it.
1.96Nm (0.8+ - 0.20Kgfm)

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

02/00
Page 6-
6-49
13. Installation of
ELEMENT
1) Install PLUNGER
Install PLUNGER so as
end of PLUNGER to match
the cut of LOWER SEAT.
2) Install ELEMENT
carefully preventing from
damage to PLUNGER.
Apply grease to O-ring.

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump D & A TPK

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Page 6-
6-50
3) Tighten bolts alternately

to fix ELEMENT.
1.97Nm (0.65+ -0.20Kgfm)

SAA6D140/125--CRI
SAA6D140/125
Fuel Pump Bench Testing TPK

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Page 6-
6-51
Resistance
Measure the
resistance on G
sensor and
PCV solenoid.
CRITERIA: See right
hand photo
Note: Please use T-
Adapter to measure
the resistance. Do
not touch the pins in
connector directly
like this training.

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-52
CRITERIA

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-53
Adjustment
1. Preparation
1) Connect PRESSURE
GUIDE to PRESSURE
REGULATOR and loosen
FLOW DUMPERS in two
positions with SOCKET
WRENCH.
2) Hit out inner parts with
PIN REMOVING BAR
being careful to prevent
from damage on SEAL of
FLOW DAMPER. ø3 BAR

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-54
4) Install STEEL BALL and

tighten it with CAP NUT.
5.0Nm m(5.0+ -0.5Kgfm)
3) Put the FLOW DUMPER,
whose inner parts are
removed, on COMMON RAIL
again.
4.9Nm
(10.0+ -0.5Kgfm)

SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-55

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-56
2. BENCH setting
(Note: Photos is not matched
for process connecting pipes.
Please see Photos as
your reference.)
1) Install PUMP HOUSNG
STAND on a bench (Temporal)
2) Install TIMER JOINT on the
bench
95091-10840(ø25)
95091-10840(ø35)

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-57
3) Install SUPPY PUMP on the

PUMP HOUSING STAND.
4) Connect couplings of PUMP and

the BENCH
5) Tighten bolt to fix PUMP FIXING

BRACKET.
6) Centering CAMSHAFT and

coupling by rotating drive shaft.
7) Tighten nuts to connect

COUPLING JOINT.
SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-58
8) Set FUEL FILTER

BRACKET on the BENCH.
9) Connect pipe to
(High--pressure outlet check)
(High
10) Connect the pipe from
to COMMON RAIL. And use
FLOW
DAMPER which is installed
with STEEL BALL and screw
with hexagonal hole.
NUT CAP 95091-
95091-11350
JET PIPE 95091-
95091-
11390(L500:outer thread)
SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-59
11) Install PRESSURE GAUGE to a

FLOW DAMPER whose inner parts
are removed.
GAUGE 95805-10290
ADAPTER : 95091-11370
JET PIPE 95091-
11400(L500:internal thread)

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SAA6D140/125

02/00
Page 6-
6-60
12) Connect IN Inside of

PRESSURE REGULATOR and
a FLOW DAMPER whose
inner parts are removed.
JET PIPE 95091-
1400(L500:internal thread )
13) Connect OUT side of
PRESSURE REGULATOR to a
nozzle. JET PIPE 95091-
11410(L900:internal thread)

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-61
15) Connect outlet of PUMP

to BENCH (to
TANK) with OVERFLOW
HOSE. And connect
PRESSURE LIMIT of
COMMON RAIL TO
BENCH (LEAKAGE). Finally
out SAFETY
COVER on couplings.
JPOMT NIPPLE: 95091-
11420
COVER: 95095-10580

SAA6D140/125--CRI
SAA6D140/125

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Page 6-
6-62
16) Connect FUEL FILTER to

PUMP with fuel
hose.
17) Connect FUEL HOSE IN
side of FEED
PUMP for self-suction
purpose and insert
another one to FUEL TANK
of BENCH.
18) Set up wiring harness of
PCV, G SENSOR,
CONRLLER and so on.

SAA6D140/125--CRI
SAA6D140/125

02/00
Page 6-
6-63

CRI-EnG06.2 DisassyAssy FuelPump

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Technical Presentation Kit

Disassembly & Assembly

Fuel Pump D & A TPK

Parts of CRI supply pump

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Tools for BENCH Test

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

2) Attach PUMP with four

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Remove ELEMENT Assembly

Tighten PCV PULLER bolts evenly

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Mark the No.1

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Remove STOPPER with

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Loosen vice and change mounting

Remove VALVE HOLDER

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Remove VALVE, SPRING,

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Removal of UPPER SPRING

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

•Attach the UPPER

Note: Do not press with

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Drain LUB OIL from pump housing

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Remove SIDE PLATE (outer)

Remove CASING with

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Remove OUTER ROTOR5)

Remove SIDE PLATE

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

Removal of FEED PUMP

1) Remove FEED PUMP housing from SUPPLY PUMP

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

1) Remove FEED PUMP housing from SUPPLY

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

2) Remove the bolts for

KT900201 - Disassembly & Assembly Menu Exit

Fuel Pump D & A TPK

KT900201 - Disassembly & Assembly Menu Exit