COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL PRESSURE DISCHARGE VALVE

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2. INSTALL FUEL PRESSURE SENSOR

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3. INSTALL COMMON RAIL ASSEMBLY

   1. Install the common rail assembly to the cylinder head cover sub-assembly.

   2. Using an E10 "TORX" socket wrench, install the 2 common rail assembly brackets with the 4 bolts.

      Tip:

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

   3. Connect the fuel return tube.

   4. Connect the pressure discharge valve connector.

   5. Connect the fuel pressure sensor connector.

4. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

   Note:

   • If the pressure lines are leaking after installation, they must be replaced.

   • Do not overtighten the pressure lines.

   1. 

      Install the fuel inlet pipe sub-assembly to the rubber grommet and rubber mount as shown in the illustration.

      Table 1. Text in Illustration

      *1	Rubber Grommet
      *2	Rubber Mount

      Note:

      Install the rubber mount and rubber grommet at the correct positions on the pressure line.

   2. Temporarily install the union nut at the fuel supply pump assembly end and common rail assembly end of the fuel inlet pipe sub-assembly by hand.

   3. Using SST, tighten the union nut at the fuel supply pump assembly end and common rail assembly end of the fuel inlet pipe sub-assembly as shown in the illustration.

      SST

      PZ4TB-04959-10

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

5. INSTALL INJECTION PIPE SUB-ASSEMBLY

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6. INSTALL INTAKE MANIFOLD

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7. INSPECT FOR FUEL LEAK

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