COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, 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

    		 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 common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck or dropped.

  • Hold the common rail assembly itself during removal and installation. Do not hold the pressure discharge valve or fuel pressure sensor, etc.

  • 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

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

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  5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)

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  7. INSTALL WIRING HARNESS CLAMP BRACKET

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  8. INSTALL EGR VALVE ADAPTER SUB-ASSEMBLY (w/o EGR Cooler)

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  9. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)

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  10. INSTALL EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  12. BLEED AIR FROM FUEL SYSTEM

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  13. INSPECT FOR FUEL LEAK

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