COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the fuel pressure sensor connector to the common rail assembly.

    3. Attach the wire harness clamp.

  2. INSTALL NO. 4 FUEL HOSE


    1. Connect the No. 4 fuel hose to the common rail assembly, and slide the clamp to secure it.

  3. TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  4. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  7. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  8. INSTALL EGR COOLER ASSEMBLY

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  10. BLEED AIR FROM FUEL SYSTEM

    Click here

  11. INSPECT FOR FUEL LEAK

    Click here