COMMON RAIL INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE

  1. INSTALL PRESSURE DISCHARGE VALVE ASSEMBLY

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  2. INSTALL FUEL PRESSURE SENSOR

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  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.

      Tip:

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

    3. Connect the fuel return tube.

    4. Connect the pressure discharge valve assembly 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. A354353C01

      *1

      Rubber Grommet

      *2

      Rubber Mount

      Install the fuel inlet pipe sub-assembly to the rubber grommet and rubber mount 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 nuts 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 nuts at the fuel supply pump assembly end and common rail assembly end of the fuel inlet pipe sub-assembly in the order shown in the illustration.

      SST

      PZ4TB-04959-10

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Note:

      • Be careful not to bend the pressure line with SST.

      • Always reposition SST before it contacts the pressure line.

  5. INSTALL INJECTION PIPE SUB-ASSEMBLY

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  6. INSTALL INTAKE MANIFOLD

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  7. INSPECT FOR FUEL LEAK

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