COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

  • w/ DPF:

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.

PROCEDURE


  1. INSTALL COMMON RAIL ASSEMBLY RH


    1. Install the common rail with the 2 bolts.

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

  2. INSTALL INJECTION PIPE RH

    Click here

  3. INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  4. CONNECT FUEL PUMP MOTOR WIRE

    Click here

  5. INSTALL COMMON RAIL ASSEMBLY LH


    1. Install the common rail with the 2 bolts.

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

  6. INSTALL NO. 5 NOZZLE LEAKAGE PIPE


    1. Install a new gasket and the leakage pipe with the union bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note

      Make sure there is no foreign matter or damage on the seal surface.

    2. w/ DPF:

      Connect the fuel hose.

  7. INSTALL NO. 2 FUEL PIPE (w/ DPF)


    1. Install the No. 2 fuel pipe with the union bolt and bolt.

      Torque:
      for union bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Install the No. 4 fuel hose.

  8. INSTALL CYLINDER HEAD COVER SILENCER RH (w/ DPF)

    Click here

  9. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  10. INSTALL INJECTION PIPE LH

    Click here

  11. INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  12. INSTALL CYLINDER HEAD COVER SILENCER LH (w/ DPF)

    Click here

  13. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  14. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

    Click here

  15. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

  16. CONNECT ENGINE WIRE

    Click here

  17. INSTALL NO. 4 WATER BY-PASS PIPE

    Click here

  18. INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  19. CONNECT FUEL HOSE

    Click here

  20. INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  21. INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  22. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  23. INSTALL NO. 4 AIR TUBE

    Click here

  24. INSTALL NO. 2 AIR HOSE

    Click here

  25. INSTALL NO. 3 AIR TUBE

    Click here

  26. INSTALL NO. 1 AIR HOSE

    Click here

  27. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  28. INSTALL INTAKE AIR CONNECTOR

    Click here

  29. TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

    Click here

  30. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  31. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  32. INSTALL NO. 1 GAS FILTER

    Click here

  33. INSTALL AIR TUBE SUB-ASSEMBLY LH

    Click here

  34. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  35. INSTALL AIR TUBE SUB-ASSEMBLY RH

    Click here

  36. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  37. CONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  38. INSTALL INTERCOOLER ASSEMBLY

    Click here

  39. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  40. ADD ENGINE COOLANT

    Click here

  41. INSPECT FOR FUEL LEAK

    Click here

  42. INSPECT FOR COOLANT LEAK

    Click here

  43. INSPECT FOR OIL LEAK

    Click here

  44. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  45. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  46. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  47. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here