COMMON RAIL (w/ EGR Cooler) INSTALLATION

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • When replacing the common rail, do not remove the foreign object mixing prevention caps of the common rail until just before the fuel inlet pipe and injection pipe are connected to the common rail.


  1. INSTALL COMMON RAIL ASSEMBLY


    1. A01DYVV

      Install the common rail and No. 2 intake manifold insulator with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    2. Connect the 2 connectors.

  2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E0JCE01

      Temporarily install the fuel inlet pipe with the union nuts.

      Note


      • If the supply pump is replaced, the fuel inlet pipe must be replaced.

      • Keep the fuel inlet pipe free of foreign matter.

    2. ) Install a new O-ring to the oil level gauge guide, and install the oil level gauge guide to the cylinder block.

      Note

      Apply a coat of engine oil to the O-ring.

    3. A01E1CP

      Temporarily install the stay of the oil level gauge guide to the intake manifold with the bolt.

    4. A01E1Y9E01

      Install the clamp with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      Install the clamp so that the fuel inlet pipe marking can be seen on both sides of the clamp.

    5. Tighten the bolt of the oil level gauge guide stay.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. A01DXS1E03

      Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.

      Torque:
      without union nut wrench
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      with union nut wrench
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.

      • Make sure union nut wrench and wrench are connected in a straight line.

    7. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the supply pump side.

      Torque:
      without union nut wrench
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      with union nut wrench
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.

      • Make sure union nut wrench and wrench are connected in a straight line.

  3. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    A01DVSC

    1. Temporarily install the leakage pipe with the 3 bolts.

    2. Temporarily install a new gasket with the check valve.

    3. Tighten the 3 bolts and check valve.

      Torque:
      for check valve
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    4. Connect the 3 fuel hoses.

  4. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

    • Keep the joints of the injection pipe clean.


    1. A01E10I

      Temporarily install the No. 4 injection pipe with the union nuts.

    2. Install the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

      • Make sure that the inner-rubbers of the injection pipe fit inside the clamp.

      • When installing the pipe, check that the inner rubbers and the clamp are in their proper positions.

    3. A01DVF3E02

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 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. Using a union nut wrench, tighten the injection pipe union nuts on the injector side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 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.

  5. INSTALL EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE


    1. Install the EGR cooler with electric EGR control valve and No. 2 EGR valve Click here.

  6. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing the injector, also replace the injection pipe.

    • Keep the joints of the injection pipe clean.


    1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

    2. A01E1MAE02

      Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts, as shown in the illustration.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

      If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

    3. A01E2WGE01

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 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. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 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.

  7. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter installation surface.

    2. Apply clean engine oil to the gasket of a new oil filter.

    3. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.

    4. A01DY82E02

      Using SST, tighten the oil filter. Depending on the work space available, choose from the following.

      SST
      09228-07501

      1. If enough space is available, use a torque wrench to tighten the oil filter.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 turn by hand or with a common wrench.

  8. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. w/o EGR Cooler:


      1. A01DWLBE01

        Install the stay with the 2 bolts.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

        Tech Tips

        The manifold stay indented area (labeled A) must face the manifold.

    2. w/ EGR Cooler:


      1. A01E1Y6

        Install the manifold with the 2 bolts.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      2. Connect the 3 vacuum hoses and 2 VSV connectors.

  9. INSTALL INTERCOOLER ASSEMBLY


    1. Install the intercooler assembly Click here.

  10. INSTALL FUEL TANK CAP ASSEMBLY

  11. ADD ENGINE OIL


    1. Wipe the oil pan and drain plug.

    2. Install a new gasket and the drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

    3. Add new oil.

      Standard oil capacity
      Item Specified Condition
      Drain and refill with oil filter change 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Drain and refill without oil filter change 6.6 liters (7.0 US qts, 5.8 Imp. qts)
      Dry fill 7.4 liters (7.8 US qts, 6.5 Imp. qts)

    4. Install the oil filler cap.

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  13. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      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. A01DVKYE03

      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.

      A01DYT1E05

      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.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    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. INSPECT FOR OIL LEAK

  15. INSPECT FOR FUEL LEAK

    A01E2N9E01

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine is stopped.

      If there is fuel leakage, repair or replace parts as necessary.

    2. Start the engine and check that there are no leaks from any part of the fuel system.

      If there is fuel leakage, repair or replace parts as necessary.

    3. Disconnect the return hose from the common rail.

    4. Start the engine and check for fuel leaks from the return pipe.

      If there is fuel leakage, replace the common rail.

    5. Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

    8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

      If there is fuel leakage, repair or replace parts as necessary.

    10. Reconnect the return hose to the common rail.

  16. REMOVE NO. 2 ENGINE UNDER COVER


    1. Install the under cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  17. REMOVE NO. 1 ENGINE UNDER COVER


    1. Install the under cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }