Common Rail -- Installation |
- NOTICE:
- When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, 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
- 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
- Injector assembly (including shuffling the injector assemblies between the cylinders)
- 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 |
Install the common rail assembly with the 2 nuts.
- Torque:
- 21 N*m{214 kgf*cm, 15 ft.*lbf}
Connect the fuel pressure sensor connector to the common rail assembly.
Attach the wire harness clamp.
| 2. INSTALL NO. 4 FUEL HOSE |
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 |
Temporarily install the 2 No. 2 injection pipe sub-assemblies 4 union nuts.
Temporarily install the 2 No. 1 injection pipe sub-assemblies 4 union nuts.
| 4. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY |
Using SST, tighten the No. 1 and No. 2 injection pipe sub-assemblies 8 union nuts.
Text in Illustration *a Torque Wrench Fulcrum Length - Torque:
- Specified tightening torque:
- 40 N*m{214 kgf*cm, 15 ft.*lbf}
- HINT:
- 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 |
- NOTICE:
- When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe subassembly, 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.
Temporarily install the fuel inlet pipe sub-assembly.
Install 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}
Using SST, tighten the fuel inlet pipe sub-assembly union nut on the common rail side sub-assembly.Text in Illustration *a Torque Wrench Fulcrum Length - SST
- 09245-11010
- Torque:
- Specified tightening torque:
- 40 N*m{408 kgf*cm, 30 ft.*lbf}
- HINT:
- 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)
 |
Using a 19 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply pump assembly side.Text in Illustration *a Torque Wrench Fulcrum Length - Torque:
- Specified tightening torque:
- 48 N*m{489 kgf*cm, 35 ft.*lbf}
- HINT:
- 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 |
Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.
Tighten the 2 union bolts and bolts in the order shown in the illustration.Text in Illustration 
Union Bolt 
Bolt - Torque:
- union bolt:
- 42 N*m{428 kgf*cm, 31 ft.*lbf}
- bolt:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
 |
Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe (LandCruiser RM0000028RU05SX.html).
| 7. INSTALL WIRING HARNESS CLAMP BRACKET |
Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly.
- Torque:
- 10 N*m{102 kgf*cm, 7 ft.*lbf}
Connect the pressure discharge valve connector to the common rail assembly.
| 8. INSTALL EGR COOLER ASSEMBLY |
| 9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected. (LandCruiser RM000003YMF011X.html)
| 10. BLEED AIR FROM FUEL SYSTEM |
| 11. INSPECT FOR FUEL LEAK |