COMMON RAIL > INSTALLATION

for Preparation Click here



1. INSTALL COMMON RAIL ASSEMBLY

NOTICE:
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.



    A098899E01

  1. Install the common rail with the 2 bolts.

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

  1. Connect the fuel pressure sensor connector.



2. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


A098974E01

  1. Temporarily install the fuel inlet pipe with the union nuts.

    NOTICE:
    1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
    2. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.

  1. Using SST, tighten the inlet pipe union nut on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

  1. Using SST, tighten the inlet pipe union nut on the supply pump side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

  1. Install the oil level gauge guide with the 2 bolts.

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



    G036615E01

  1. Install the clamp with the bolt.

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



3. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


A098898E01

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

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

  1. Fully tighten the 3 bolts and check valve.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf } for check valve
    13 N*m{ 133 kgf*cm , 10 ft.*lbf } for bolt

  1. Connect the 2 fuel hoses.



4. INSTALL INJECTION PIPE


G038585E02

NOTICE:
  1. When replacing the injector, also replace the injection pipe.
  2. 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.

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

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

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



    A098972E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



    A098893E01

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

  1. Install 2 new injection pipe clamps with the 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    NOTICE:
    1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
    2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.



    A098973E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



5. INSTALL OIL FILTER SUB-ASSEMBLY

  1. Check and clean the oil filter installation surface.

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

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



    A060101E01

  1. 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.



6. INSTALL MANIFOLD STAY


A099932E01

  1. Install the stay with the 2 bolts.

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

    HINT:
    The stay's indented area (labeled A) must face the manifold.



7. INSTALL CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    A112150

  1. Install a new gasket and the intake air connector with the 4 bolts.

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



    A112149

  1. Using a 22 mm deep socket wrench, install a new gasket and the IAT sensor.

    Torque:
    29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }



    A110367E01

  1. Install the CAC with the 4 bolts.

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for bolt A

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

  1. Tighten the 4 hose clamps of the No. 1 and No. 2 air hose.

    Torque:
    6.5 N*m{ 66 kgf*cm , 58 in.*lbf }

  1. Connect the diesel turbo IAT sensor connector.



8. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    A110362

  1. Install the cover with the 3 bolts and 2 nuts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



9. ADD FUEL


10. TIGHTEN FUEL TANK CAP ASSEMBLY


11. ADD ENGINE OIL


12. BLEED AIR FROM FUEL SYSTEM


A098962E01

  1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.



13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


14. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.



15. CHECK FOR ENGINE OIL LEAKS


16. CHECK FOR FUEL LEAKS


17. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 2 bolts.

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



18. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 2 bolts.

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