COMMON RAIL(w/ Glow Plug Controller) INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the injector assemblies (including exchanging the injector assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.

  • When replacing the injector assemblies, supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.

PROCEDURE


  1. INSTALL COMMON RAIL ASSEMBLY


    1. Engage the clamp to install the hose clamp to the common rail assembly.

    2. Engage the clamp, and while connecting the No. 4 water by-pass hose, install the common rail assembly to the cylinder head sub-assembly.

    3. Install the 2 bolts.

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

    4. Connect the No. 2 fuel hose to the common rail assembly and slide the clip to secure it.

    5. Connect the pressure control valve connector.

    6. Connect the rail pressure sensor connector.

  2. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note

    To prevent contamination by foreign matter, do not remove the plastic bag that is protecting the connector portion of the injector assembly and common rail assembly until immediately before installing the No. 4 injection pipe sub-assembly.


    1. B00421DC11
      *a Correct
      *b Incorrect

      Temporarily install a new No. 4 injection pipe sub-assembly to the injector assembly and common rail assembly.

      Note


      • When installing, the sealing surface of the No. 4 injection pipe sub-assembly should be fitted tightly against the injector assembly and common rail assembly.

      • When installing, do not tilt or angle the sealing surface of the No. 4 injection pipe sub-assembly.

      • When installing, tighten the union nut of the No. 4 injection pipe sub-assembly by hand until it cannot be turned any further.

    2. B0041WBC01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, fully tighten the 2 union nuts in the order shown in the illustration.

      Torque:
      Specified tightening torque
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      When fully tightening the union nuts, make sure to tighten from the common rail assembly side.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (245 kgf*cm, 18 ft.*lbf)

  3. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note

    To prevent contamination by foreign matter, do not remove the plastic bag that is protecting the connector portion of the injector assembly and common rail assembly until immediately before installing the fuel inlet pipe sub-assembly.


    1. B00421DC04
      *a Correct
      *b Incorrect

      Temporarily install a new fuel inlet pipe sub-assembly to the supply pump assembly and common rail assembly.

      Note


      • When installing, the sealing surface of the fuel inlet pipe sub-assembly should be fitted tightly against the injector assembly and common rail assembly.

      • When installing, do not tilt or angle the sealing surface of the fuel inlet pipe sub-assembly.

      • When installing, tighten the union nut of the fuel inlet pipe sub-assembly by hand until it cannot be turned any further.

    2. B00442AC01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, fully tighten the 2 union nuts in the order shown in the illustration.

      Torque:
      Specified tightening torque
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      When fully tightening the union nuts, make sure to tighten from the common rail assembly side.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (245 kgf*cm, 18 ft.*lbf)

    3. Install the No. 2 injection pipe clamp to the fuel inlet pipe sub-assembly and No. 4 injection pipe sub-assembly with the bolt.

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

    4. Install the No. 3 engine cover bracket to the EGR cooler bracket with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  4. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note

    To prevent contamination by foreign matter, do not remove the plastic bag that is protecting the connector portion of the injector assembly and common rail assembly until immediately before installing the No. 3 injection pipe sub-assembly.


    1. B00421DC11
      *a Correct
      *b Incorrect

      Temporarily install a new No. 3 injection pipe sub-assembly to the injector assembly and common rail assembly.

      Note


      • When installing, the sealing surface of the No. 3 injection pipe sub-assembly should be fitted tightly against the injector assembly and common rail assembly.

      • When installing, do not tilt or angle the sealing surface of the No. 3 injection pipe sub-assembly.

      • When installing, tighten the union nut of the No. 3 injection pipe sub-assembly by hand until it cannot be turned any further.

    2. B0042JHC01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, fully tighten the 2 union nuts in the order shown in the illustration.

      Torque:
      Specified tightening torque
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      When fully tightening the union nuts, make sure to tighten from the common rail assembly side.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (245 kgf*cm, 18 ft.*lbf)

    3. Install the vacuum transmitting pipe sub-assembly to the EGR cooler bracket with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Connect the vacuum hose to the No. 2 EGR valve assembly.

  5. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Note

    To prevent contamination by foreign matter, do not remove the plastic bag that is protecting the connector portion of the injector assembly and common rail assembly until immediately before installing the No. 2 injection pipe sub-assembly.


    1. B00421DC11
      *a Correct
      *b Incorrect

      Temporarily install a new No. 2 injection pipe sub-assembly to the injector assembly and common rail assembly.

      Note


      • When installing, the sealing surface of the No. 2 injection pipe sub-assembly should be fitted tightly against the injector assembly and common rail assembly.

      • When installing, do not tilt or angle the sealing surface of the No. 2 injection pipe sub-assembly.

      • When installing, tighten the union nut of the No. 2 injection pipe sub-assembly by hand until it cannot be turned any further.

    2. B0043C0C01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, fully tighten the 2 union nuts in the order shown in the illustration.

      Torque:
      Specified tightening torque
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      When fully tightening the union nuts, make sure to tighten from the common rail assembly side.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (245 kgf*cm, 18 ft.*lbf)

  6. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Note

    To prevent contamination by foreign matter, do not remove the plastic bag that is protecting the connector portion of the injector assembly and common rail assembly until immediately before installing the No. 1 injection pipe sub-assembly.


    1. B00421DC11
      *a Correct
      *b Incorrect

      Temporarily install a new No. 1 injection pipe sub-assembly to the injector assembly and common rail assembly.

      Note


      • When installing, the sealing surface of the No. 1 injection pipe sub-assembly should be fitted tightly against the injector assembly and common rail assembly.

      • When installing, do not tilt or angle the sealing surface of the No. 1 injection pipe sub-assembly.

      • When installing, tighten the union nut of the No. 1 injection pipe sub-assembly by hand until it cannot be turned any further.

    2. B00450EC01
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, fully tighten the 2 union nuts in the order shown in the illustration.

      Torque:
      Specified tightening torque
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Note

      When fully tightening the union nuts, make sure to tighten from the common rail assembly side.

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (245 kgf*cm, 18 ft.*lbf)

  7. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Note

    Perform installation and removal procedures by hand only. Do not use any tools.


    1. B0042PCC03
      *a Lock Bush
      *b Correct
      *c Incorrect

      Check that the lock bush of the nozzle leakage pipe assembly is at the highest position.

    2. Insert the rest arm into the upper surface of the injector assembly, and while pressing the return plug from both sides, insert the nozzle leakage pipe assembly into each injector assembly.

      B00432MC01
      *a Lock Bush *b Return Plug
      *c Rest Arm - -
      B0043HC Push B00420Y Hold

    3. While holding down the return plug, push the lock bush until it meets the top position of the return plug, and secure the nozzle leakage pipe assembly in place.

    4. Engage the clamp to connect the nozzle leakage pipe assembly to the hose clamp.

    5. Connect the nozzle leakage pipe assembly to the No. 2 nozzle leakage pipe and slide the clip to secure it.

  8. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  9. INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

  10. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  11. PERFORM INITIALIZATION AND REGISTRATION

    Click here

  12. BLEED AIR FROM FUEL SYSTEM

    Click here

  13. INSPECT FOR FUEL LEAK

    Click here

  14. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    Click here