COMMON RAIL(w/o 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, it is necessary to replace the injection pipes with new ones.

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

PROCEDURE


  1. INSTALL COMMON RAIL ASSEMBLY


    1. A01TB5C

      Install the common rail assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01TBGP

      Connect the connector to the common rail assembly.

  2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01TARXC04
    *a Correct
    *b Incorrect

    Note


    • When replacing the supply pump assembly, the fuel inlet pipe sub-assembly must also be replaced.

    • Replace the fuel inlet pipe sub-assembly with a new one when the fuel inlet pipe sub-assembly has been removed and reinstalled more than 5 times.


    1. A01TDDJ

      Temporarily install the fuel inlet pipe sub-assembly onto the supply pump assembly and common rail assembly.

      Note

      Install the fuel inlet pipe sub-assembly and union nut vertically, not at a tilt.

    2. Using a 17 mm union nut wrench, tighten the union nut on the common rail assembly side.

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

      Click here

    3. Using a 17 mm union nut wrench, tighten the union nut on the supply pump assembly side while holding the supply pump assembly with a 17 mm wrench.

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

      Note

      Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

      Click here

    4. Connect the fuel hose, and slide the clip to secure it.

  3. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Click here

  4. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  5. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  6. INSTALL NO. 1 EGR COOLER BRACKET

    Click here

  7. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY

    Click here

  8. BLEED AIR FROM FUEL SYSTEM

    Click here

  9. INSPECT FOR FUEL LEAK

    Click here