COMMON RAIL INSTALLATION


  1. INSTALL COMMON RAIL ASSEMBLY

    A01KHS5

    1. Install the common rail assembly with the 3 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    2. Connect the sensor connectors.

  2. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY NO.2

    A01KHU4
    Torque:
    Bolt
    12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }
    Union bolt
    12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }
    Check valve
    21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  3. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  4. INSTALL INJECTION PIPE SET

    Click here

  5. BLEED INJECTION PIPE


    1. Move the priming pump of the fuel filter up and down until it becomes hard.

  6. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  7. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  8. INSTALL VSV ASSEMBLY

  9. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Install the front door scuff.

    2. Install the floor mat.

    3. Install the engine service hole sub cover with the 7 bolts.

  10. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  11. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  12. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Install the clip and nut, and then connect the shift cable to the transmission.

  13. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Install the clip and nut, and then connect the select cable to the transmission.

  14. INSTALL FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)

    Click here

  15. INSTALL FRONT SEAT ASSEMBLY RH (W/O TILT CAB CAB TYPE)

    Click here

  16. INSTALL ENGINE OIL

    Click here

  17. INSTALL BATTERY NEGATIVE TERMINAL

  18. INSPECT FUEL LEAK

    CAUTION:


    • During ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud, so pay attention.

    • During ACTIVE TEST mode, fuel becomes high pressure, so take much care not to expose your eyes, hands, or body to the fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine stops.

      If there is fuel leakage, replace those parts.

    2. While cranking or starting the engine, check that there are no leaks from any part of the fuel system.

      If there is fuel leakage, replace those parts.

    3. Disconnect the return hose from the common rail.

    4. While cranking the engine, check fuel leakage from the return pipe.

      If there is fuel leakage, replace the common rail assembly Click here.

    5. A01KFQVE01
      Text in Illustration
      *1 Intelligent Tester

      Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the FUEL LEAK test of ACTIVE TEST mode on the intelligent tester.

    8. If you have no intelligent tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable.

      If there is fuel leakage, replace those parts.

    10. Reconnect the return hose to the common rail.

  19. CHECK ENGINE OIL

    Click here

  20. CHECK ENGINE OIL LEVEL

    Click here