COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail and No. 2 intake manifold insulator with the 2 bolts.

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

    2. Connect the fuel pressure sensor connectors and pressure discharge valve connector.

  2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  3. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B001H81E01
      Text in Illustration
      *1 Union Bolt

      Temporarily install the No. 2 nozzle leakage pipe with the 4 bolts.

    2. Temporarily install a new gasket and the union bolt.

    3. Tighten the 4 bolts and union bolt.

      Torque:
      for bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Connect the 3 fuel hoses.

  4. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  5. INSTALL VACUUM CONTROL VALVE SET

    Click here

  6. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  7. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE

    Click here

  8. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)

    Click here

  9. CONNECT ENGINE WIRE (w/o EGR System)

    Click here

  10. INSTALL AIR CONNECTOR STAY (w/o EGR System)

    Click here

  11. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  12. INSTALL THROTTLE BODY BRACKET (w/o EGR System)

    Click here

  13. INSTALL NO. 1 INTAKE PIPE (w/o EGR System)

    Click here

  14. CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  15. CONNECT INLET HEATER WATER HOSE (w/o EGR System)

    Click here

  16. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Install the electric EGR control valve assembly Click here.

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  18. ADD ENGINE COOLANT (w/ EGR System with EGR Cooler)

    Click here

  19. BLEED AIR FROM FUEL SYSTEM

    Click here

  20. INSPECT FOR COOLANT LEAK (w/ EGR System with EGR Cooler)

    Click here

  21. INSPECT FOR FUEL LEAK

    Click here

  22. INSPECT FOR OIL LEAK

    Click here

  23. INSPECT ENGINE OIL LEVEL

    Click here