COMMON RAIL INSTALLATION


  1. INSTALL COMMON RAIL ASSEMBLY


    1. A01174B

      Install the common rail assembly with 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A011A9E

      Connect the connector.

  2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A011ADSE01

    Note


    • When replacing the common rail, the fuel inlet pipe must also be replaced.

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


    1. A0119YI

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

      Note

      Install the pipe and union nut vertically, not at a tilt.

    2. Using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the common rail side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 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 wrench (17 mm), hold the supply pump, and using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the supply pump side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 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.

      • After installing the fuel inlet pipe, confirm that the retainer spring is engaged correctly.

    4. Connect the No. 2 fuel hose.

  3. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    A0117KJE01
    Text in Illustration
    *1 No. 1 Injection Pipe
    *2 No. 2 Injection Pipe
    *3 No. 3 Injection Pipe

    1. A011ADSE01

      Temporarily install 4 new injection pipes onto the injectors and common rail.

      Note

      Install the pipe and union nut vertically, not at a tilt.

    2. Using a union nut wrench (17 mm), tighten the injection pipe union nut on the common rail, and then tighten the union nut on the injector.

      Torque:
      28 N*m  { 286 kgf*cm, 20 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. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  5. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  6. INSTALL NO. 1 INJECTION PIPE CLAMP


    1. A011970

      Install both sides of the No. 1 injection pipe clamp with the 2 nuts as shown in the illustration.

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

  7. INSTALL NO. 2 INJECTION PIPE CLAMP


    1. A0118JH

      Install both sides of the No. 2 injection pipe clamp with the nut as shown in the illustration.

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

  8. INSTALL NO. 1 EGR COOLER BRACKET


    1. A0117LI

      Install the No. 1 EGR cooler bracket with the 2 bolts.

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

    2. Connect the vacuum hose.

  9. INSTALL EGR WITH COOLER PIPE ASSEMBLY


    1. Install the EGR with cooler pipe assembly Click here.

  10. BLEED AIR FROM FUEL SYSTEM

    Click here

  11. INSPECT FOR FUEL LEAK


    1. Connect an intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

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

    5. Perform the Active Test.

      Intelligent Tester Display Test Details Control Range Diagnostic Notes
      Test the Fuel Leak Pressurize common rail internal fuel pressure, and check for fuel leaks Stop/Start

      Perform inspection of the high pressure fuel system.

      Test is possible when the following conditions are met:


      • Warmed up engine.

      • Vehicle is stopped.

      • Battery voltage is 12 V or more.

      • PM regeneration is not operating.

      • Engine speed is less than 4000 rpm.

      Results of real-vehicle check:


      • Engine Speed: 2702 rpm


      • Fuel Pressure: 108570 kPa


      • Target Common Rail Pressure: 105500 kPa


      • Target Pump SCV Current: 1.2 A


      • MAP: 127 kPa


      • MAF: 28 g/sec.