INTAKE MANIFOLD INSTALLATION

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.

INSTALL INTAKE MANIFOLD

Install a new gasket to the cylinder head.

Tech Tips

Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

Text in Illustration
*1	Nut

Install the intake manifold with the 7 bolts and 2 nuts.

Torque:: 23 N*m { 235 kgf*cm, 17 ft.*lbf }

Bolt Length

Item	Length
Bolt A	90 mm (3.54 in.)
Bolt B	25 mm (0.984 in.)

CONNECT NO. 2 VACUUM TRANSMITTING HOSE
1. Connect the No. 2 vacuum transmitting hose to the intake manifold.
INSTALL NO. 2 INTAKE MANIFOLD
1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
INSTALL ENGINE COVER BRACKET
1. Install the engine cover bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL GAS FILTER BRACKET
1. Install the gas filter bracket with the 2 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
INSTALL NO. 1 GAS FILTER
1. Text in Illustration
  
  *1 Protrusion
  
  *2 Groove
  
  Install the No. 1 gas filter to the gas filter bracket.
  
  Note
  
  Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.
2. Connect the vacuum hose.
INSTALL DIESEL TURBO PRESSURE SENSOR
1. Text in Illustration
  
  *1 Protrusion
  
  Install the sensor with the bolt.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
  
  Note
  
  Make sure the protrusion of the gas filter bracket is inserted into the hole of the sensor.
2. Connect the sensor connector.
3. Connect the vacuum hose.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install a new O-ring to the engine oil level dipstick guide.
2. Install the engine oil level dipstick guide with the 2 bolts.
  
  Torque:
  
  33 N*m { 337 kgf*cm, 24 ft.*lbf }
3. Connect the connector and attach the wire harness clamp to the engine oil level dipstick guide.
4. Install the engine oil level dipstick.
INSTALL INTAKE MANIFOLD INSULATOR
1. Install the intake manifold insulator to the intake manifold.
INSTALL COMMON RAIL ASSEMBLY
1. Install the common rail with the 2 bolts.
  
  Torque:
  
  21 N*m { 209 kgf*cm, 15 ft.*lbf }
2. Using pliers, grip the claws of the clip and slide the clip to connect the fuel hose.
INSTALL INJECTION PIPE SUB-ASSEMBLY
1. Using a 14 mm union nut wrench, tighten the 4 nuts at the common rail end of the injection pipes.
  
  Torque:
  
  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.
2. Using a 14 mm union nut wrench, tighten the 4 nuts at the injector end of the injection pipes.
  
  Torque:
  
  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. Install the 4 injection pipe clamps with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
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.
  
  Torque:
  
  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.
  
  Torque:
  
  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.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
1. Text in Illustration
  
  *1 Protrusion
  
  Install a new gasket.
  
  Note
  
  Make sure the protrusion of the gasket is facing upward as shown in the illustration.
2. Install the electric EGR control valve.

Text in Illustration
*1	Protrusion
*2	Groove

Text in Illustration
*1	Protrusion

Text in Illustration
*1	Protrusion

INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

Install a new gasket to the electric EGR control valve.

Text in Illustration
*1	Nut

Temporarily install the No. 2 EGR pipe with the 3 bolts and 2 nuts.

Bolt Length

Item	Specified Condition
Bolt A	25 mm (0.984 in.)
Bolt B	70 mm (2.76 in.)

Tighten the 2 bolts labeled A shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Tighten the bolt and 2 nuts labeled B shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Connect the electric EGR control valve connector.

CONNECT NO. 8 WATER BY-PASS HOSE
INSTALL NO. 7 WATER BY-PASS HOSE
INSTALL EGR VALVE BRACKET
1. Install the 2 EGR valve brackets with the 3 bolts.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
2. Connect the 2 connectors and attach the 2 wire harness clamps.
CONNECT ENGINE WIRE
1. Connect the engine wire with the bolt and 3 nuts.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
2. Install the wire harness bracket with the bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
3. Attach the 2 wire harness clamps.
4. Connect the glow plug wire harness with the nut and grommet.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
5. Connect the pressure discharge valve connector.
6. Connect the fuel pressure sensor connector.
INSTALL DIESEL THROTTLE BODY ASSEMBLY
1. Install the diesel throttle body assembly Click here.
BLEED AIR FROM FUEL SYSTEM
1. 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 Click here.
7. Start the engine.*1
8. 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. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.
  
  Tech Tips
  
  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 Click here.
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.

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Tech Tips

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.

Perform Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Start the engine.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine / Active Test.

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.

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.