COMMON RAIL (w/o DPF) INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail with the 2 bolts.

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

    2. Connect the fuel hose.

    3. Connect the pressure discharge valve connector and fuel pressure sensor connector.

  2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

    • Keep the fuel inlet pipe free of foreign matter.


    1. Temporarily install the fuel inlet pipe with the union nuts.

    2. Install the No. 2 injection pipe clamp with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Install the No. 1 injection pipe clamp with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.

    4. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    5. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  3. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

    • Keep the joints of the injection pipe clean.


    1. Temporarily install the 4 injection pipes with the union nuts.

    2. Install the 2 No. 2 injection pipe clamps with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A003D1N

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. A003DVY

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    5. A003H7OE01

      Attach the 3 clamps and install the wire harness with the 4 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    6. Connect the 4 injector connectors.

  4. INSTALL EGR COOLER ASSEMBLY

    Click here

  5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  6. BLEED AIR FROM FUEL SYSTEM


    1. A003AY1E01

      Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the GTS to the DLC3.

    5. Turn the ignition switch to ON and turn the GTS on.

    6. Clear the DTCs.


    7. Start the engine.*1

    8. A003BQAE03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A003HPJE05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs.


      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  7. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurize common rail interior and check for fuel leaks Stop/Start

        • Fuel pressure inside common rail increased to specified value and engine speed increased to 2000 rpm when Active Test is performed

        • Above conditions preserved while Active Test is being performed