Click here

НАГНЕТАЮЩИЙ ТОПЛИВНЫЙ НАСОС УСТАНОВКА

Click here
Click here
Note:

  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

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

Click here
  1. Click here

    INSTALL FUEL SUPPLY PUMP ASSEMBLY


    1. A01ITMV

      Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the supply pump.

    3. A01IN19

      Install the supply pump drive coupling.

      Note:

      When reusing the coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed.

      Tip:

      Line up the coupling with the groove in the camshaft end.

    4. Install the supply pump with the 2 bolts.

      21 N*m 209 kgf*cm 15 ft.*lbf
      Tip:

      Line up the end of the supply pump drive shaft with the supply pump drive coupling.

    5. Connect the suction control valve connector.

    6. Connect the fuel temperature sensor connector.

  2. Click here

    INSTALL NO. 2 FUEL PIPE (for CCo)


    1. Temporarily install the fuel pipe and 2 new gaskets with the check valve and union bolt.

    2. Tighten the check valve.

      32 N*m 321 kgf*cm 23 ft.*lbf

    3. Tighten the union bolt.

      23 N*m 235 kgf*cm 17 ft.*lbf
  3. Click here

    INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. Temporarily install the fuel tube and 2 new gaskets with the check valve and union bolt.

    2. Tighten the check valve.

      32 N*m 321 kgf*cm 23 ft.*lbf

    3. Tighten the union bolt.

      23 N*m 235 kgf*cm 17 ft.*lbf
    4. A01IPE8

      Connect the fuel tube connector to the injector.

    5. A01IQ7XE01

      Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

      Note:

      If the fuel tube connector is not inserted to the correct position on the injector, the retainer cannot be turned far enough in the direction of the arrow.

      Table 1. Text in Illustration
      *1 Fuel Tube Connector
      *2 Injector
      *3 Retainer
      *4 O-Ring

    6. Connect the exhaust fuel addition injector connector.

  4. Click here

    INSTALL FUEL HOSE PROTECTOR (for DPF)


    1. Install the fuel hose protector with the bolt.

      21 N*m 209 kgf*cm 15 ft.*lbf
  5. Click here

    INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe with the 2 clamps and nut.

    2. Using a 14 mm union nut wrench, first tighten the nut at the common rail end of the fuel inlet pipe.

      30 N*m 306 kgf*cm 22 ft.*lbf
      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

    3. Using a 14 mm union nut wrench, tighten the nut at the supply pump end of the fuel inlet pipe.

      30 N*m 306 kgf*cm 22 ft.*lbf
      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Click here).

    4. Tighten the No. 2 injection pipe clamp nut.

      5.0 N*m 51 kgf*cm 44 in.*lbf
  6. Click here

    INSTALL NO. 1 FUEL HOSE


    1. A01IPAIE02

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 1 fuel hose.

      Table 2. Text in Illustration
      *1 Alignment Mark
      *a 1 to 5 mm (0.0394 to 0.197 in.)
      Tip:

      • Align the alignment marks and connect the hose.

      • Align the claws of the clamp with the hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the hose is 1 to 5 mm (0.0394 to 0.197 in.).

  7. Click here

    INSTALL NO. 3 FUEL HOSE


    1. A01IP1SE01

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 3 fuel hose.

      Table 3. Text in Illustration
      *a 2 to 3 mm (0.0787 to 0.118 in.)
      *b 2 to 6 mm (0.0787 to 0.236 in.)
      Tip:

      • Push on the fuel hose so that the clearance is 2 to 3 mm (0.0787 to 0.118 in.).

      • Position the clamp so that the distance from the end of the hose is 2 to 6 mm (0.0787 to 0.236 in.).

  8. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Установите корпус воздушного фильтра и закрепите его 3 болтами.

      7,0 Н*м 71 кгс*см 62 фунт-сила-дюйма
  9. Click here

    INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  10. Click here

    INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Подсоедините шланг воздушного фильтра.

    2. A01INV0E02

      Присоедините 4 зажима, чтобы закрепить крышку воздушного фильтра.

      Table 4. Обозначения на рисунке
      *a Верх

    3. Подсоедините шланг системы принудительной вентиляции картера.

    4. Подсоедините разъем датчика массового расхода воздуха и закрепите зажимом.

  11. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

  12. Click here

    PERFORM INITIALIZATION


  13. Click here

    BLEED AIR FROM FUEL SYSTEM


    1. A01IQ0Q

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note:

      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note:

      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs.


    7. Start the engine.*1

    8. A01IRMJE03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. A01IRYOE04

      Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      Tip:

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.


      1. When no DTCs are output, the air bleeding is completed.

      2. If any DTCs are output, proceed to the next step.

    13. Clear the DTCs.


    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.
  14. Click here

    INSPECT FOR FUEL LEAK

    Tip:

    Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.


    1. Perform Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        Performs inspection of the high pressure fuel system.


        • Engine Speed: 2050 rpm

        • Fuel Pressure: 172000 kPa

        • Target Common Rail Pressure: 176000 kPa

        • Target Pump SCV Current: 1400 mA

        • MAP: 176 kPa

        • MAF: 39 g/sec.
  15. Click here

    INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Введите в зацепление 4 фиксатора, чтобы закрепить крышку двигателя № 1.

  16. Click here

    INSTALL BATTERY SERVICE HOLE COVER


    1. A01ITOM

      Установите крышку технологического отверстия аккумуляторной батареи и закрепите ее фиксатором.