COMMON RAIL INSTALLATION

Note


  • Always be sure to check the tightening torque.

  • If the pressure lines are leaking after installation, they must be replaced.

  • Do not overtighten the pressure lines.


  1. INSTALL PRESSURE DISCHARGE VALVE

    Tech Tips

    Perform "Inspection After Repairs" after replacing the pressure discharge valve Click here.


    1. Check the threads and sealing surfaces for damages prior to installing the pressure discharge valve.

    2. Make sure the pressure discharge valve, sealing surfaces and threads are free from dirt and any foreign matter before performing work. Lightly grease the threads on the pressure discharge valve.

    3. Step 1:

      Screw in the pressure discharge valve by hand. Then tighten the pressure discharge valve.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    4. Step 2:

      Loosen 90°.

    5. Step 3:

      Tighten the pressure discharge valve.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  2. INSTALL FUEL PRESSURE SENSOR


    1. Check the threads and sealing surfaces for damages prior to installing the fuel pressure sensor.

    2. Make sure the fuel pressure sensor, sealing surfaces and threads are free from dirt and any foreign matter before performing work. Lightly grease the threads on the fuel pressure sensor.

    3. Screw in the fuel pressure sensor by hand. Then tighten the fuel pressure sensor.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

  3. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly to the cylinder head cover sub-assembly.

    2. Using an E10 "TORX" socket wrench, install the 2 common rail assembly brackets with the 4 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

    3. Connect the fuel return tube.

    4. Connect the pressure discharge valve connector.

    5. Connect the fuel pressure sensor connector.

  4. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • If the pressure lines are leaking after installation, they must be replaced.

    • Do not overtighten the pressure lines.


    1. A01IU59E04
      Text in Illustration
      *1 Rubber Grommet
      *2 Rubber Mount

      Install the fuel inlet pipe sub-assembly to the rubber grommet and rubber mount as shown in the illustration.

      Note

      Install the rubber mount and rubber grommet at the correct positions on the pressure line.

    2. Temporarily install the union nut at the fuel supply pump assembly end and common rail assembly end of the fuel inlet pipe sub-assembly by hand.

    3. Using SST, tighten the union nut at the fuel supply pump assembly end and common rail assembly end of the fuel inlet pipe sub-assembly as shown in the illustration.

      SST
      PZ4TB-04959-10
      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Reset SST in a timely manner to prevent bending of pressure lines.

  5. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Click here

  6. INSTALL INTAKE MANIFOLD

    Click here

  7. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch to ON and turn the GTS on.

        Note

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Actuator Test of FPC (EU5).

      4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the No. 1 integration relay, fuel suction with pump and gauge tube assembly, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the ignition switch off.

    4. Disconnect the GTS from the DLC3.