ТОПЛИВНАЯ СИСТЕМА ДВИГАТЕЛЯ COMMON RAIL УСТАНОВКА

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.


  1. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 nuts.

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

    2. Connect the fuel pressure sensor connector to the common rail assembly.

    3. Attach the wire harness clamp.

  2. INSTALL NO. 4 FUEL HOSE


    1. Connect the No. 4 fuel hose to the common rail assembly, and slide the clamp to secure it.

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


    1. Temporarily install the 2 No. 2 injection pipe sub-assemblies with the 4 union nuts.

    2. Temporarily install the 2 No. 1 injection pipe sub-assemblies with the 4 union nuts.

  4. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY


    1. B007TD1E01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using SST, tighten the 8 union nuts of the No. 1 and No. 2 injection pipe sub-assemblies.

      Torque:
      Specified tightening torque
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)

  5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note

    When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe sub-assembly, No. 1 injection pipe clamp and No. 2 injection pipe clamp with a new one. Keep the fuel inlet pipe sub-assembly free of foreign matter.


    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. Install a new No. 1 injection pipe clamp and No. 2 injection pipe clamp with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B007SYCE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using SST, tighten the fuel inlet pipe sub-assembly union nut on the common rail side sub-assembly.

      SST
      09245-11010
      Torque:
      Specified tightening torque
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)

    4. B007TNSE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 19 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply pump assembly side.

      Torque:
      Specified tightening torque
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 41 N*m (418 kgf*cm, 30 ft.*lbf)

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.

    2. B007PG4E02
      Text in Illustration
      B007QIC Union Bolt
      B007T7S Bolt

      Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      union bolt
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
      bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe Click here.

  7. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket the cylinder head cover sub-assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the pressure discharge valve connector to the common rail assembly.

  8. INSTALL EGR COOLER ASSEMBLY

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  10. BLEED AIR FROM FUEL SYSTEM

    Click here

  11. INSPECT FOR FUEL LEAK

    Click here