Common rail 2AD-FHV

Common rail 2AD-FHV
Components

Common rail 2AD-FHV Components

Common rail 2AD-FHV Components

Common rail 2AD-FHV
Removal

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE NO. 1 ENGINE COVER

 

Common rail 2AD-FHV. Detach the 4 clips and remove the engine cover.

  1. Detach the 4 clips and remove the engine cover.

3. DISCONNECT ENGINE WIRE

  1. Disconnect the fuel pressure sensor connector.

  2. Disconnect the pressure discharge valve connector.

  3. Disconnect the turbo pressure sensor connector.

  4. Remove the grommet and nut and disconnect the glow plug wire harness.

  5. Remove the 2 nuts and disconnect the engine wire from the engine cover bracket.

4. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

NOTICE:

After removing the fuel inlet pipe, cover the common rail and injection or supply pump with electrical tape to prevent dirt from entering them.

 

Common rail 2AD-FHV. Remove the nut and fuel inlet pipe clamps.

  1. Remove the nut and fuel inlet pipe clamps.

  2. Using SST, remove the fuel inlet pipe.

    SST:

    09023-38401

5. REMOVE INJECTION PIPE SUB-ASSEMBLY

NOTICE:

After removing the injection pipe, cover the common rail and injector with electrical tape to prevent dust from entering them.

 

Common rail 2AD-FHV. Remove the 2 bolts and 4 injection pipe clamps.

  1. Remove the 2 bolts and 4 injection pipe clamps.

  2. Using SST, loosen the 4 nuts at the common rail end of the injection pipes.

    SST:

    09023-38401

  3. Using SST, loosen the 4 nuts at the injector end of the injection pipes.

    SST:

    09023-38401

  4. Remove the 4 injection pipes.

6. REMOVE COMMON RAIL ASSEMBLY

 

Common rail 2AD-FHV. Using pliers, grip the claws of the clip and slide the clip to disconnect the pressure fuel hose.

  1. Using pliers, grip the claws of the clip and slide the clip to disconnect the pressure fuel hose.

  2. Remove the 2 bolts, common rail and intake manifold insulator.

Common rail 2AD-FHV
Inspection

1. INSPECT COMMON RAIL ASSEMBLY

 

Common rail 2AD-FHV. Inspect the fuel pressure sensor.

  1. Inspect the fuel pressure sensor.

    1. Measure the resistance of the sensor.

      HINT:

      Perform the inspection with no fuel pressure applied.

      Standard resistance:

      Tester Connection Specified Condition
      5 (PR) - 4 (E2) 16.4 k? or less
      2 (PR2) - 3 (E2S) 16.4 k? or less
      6 (VC) - 5 (PR) 3 k? or less
      1 (VCS) - 2 (PR2) 3 k? or less
      If the result is not as specified, replace the common rail assembly.

Common rail 2AD-FHV. Inspect the pressure discharge valve.

  1. Inspect the pressure discharge valve.

    1. Measure the resistance of the valve.

      Standard resistance:

      Tester Connection Condition Specified Condition
      1 - 2 20°C (68°F) 0.85 to 1.05 ?

      HINT:

      The temperature indicated in "Condition" is the temperature of the pressure discharge valve.

      If the result is not as specified, replace the common rail assembly.

Common rail 2AD-FHV
Installation

1. INSTALL COMMON RAIL ASSEMBLY

Common rail 2AD-FHV. Install the intake manifold insulator and common rail with the 2 bolts.

  1. Install the intake manifold insulator and common rail with the 2 bolts.

    Torque:

    20.5 N*m{ 209 kgf*cm , 15 ft.*lbf }

  2. Using pliers, grip the claws of the clip and slide the clip to connect the fuel hose as shown in the illustration.

2. INSTALL INJECTION PIPE SUB-ASSEMBLY

NOTICE:

In a case where the common rail is replaced, the injection pipes must also be replaced.

 

Common rail 2AD-FHV. Temporarily install the 4 injection pipes.

  1. Temporarily install the 4 injection pipes.

  2. Using SST, tighten the 4 nuts at the common rail end of the injection pipes.

    SST:

    09023-38401

    Torque:

    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

    HINT:

    1. Use of the proper SST is required to ensure that the correct torque is applied to the injection pipe nut.
    2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    3. Make sure that the pipe is not deformed or twisted during installation. If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new pipe.

  3. Using SST, tighten the 4 nuts at the injector end of the injection pipes.

    SST:

    09023-38401

    Torque:

    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

    HINT:

    1. Use of the proper SST is required to ensure that the correct torque is applied to the injection pipe nut.
    2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    3. Make sure that the pipe is not deformed or twisted during installation. If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new pipe.
3. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

NOTICE:

  1. In a case where the common rail is replaced, the fuel inlet pipe must also be replaced.

 

Common rail 2AD-FHV. Temporarily install the fuel inlet pipe with the 2 clamps and nut.

  1. Temporarily install the fuel inlet pipe with the 2 clamps and nut.

  2. Using SST, tighten the nut at the common rail end of the fuel inlet pipe.

    SST:

    09023-38401

    Torque:

    27 N*m{ 275 kgf*cm , 15 ft.*lbf }

    HINT:

    1. Use of the proper SST is required to ensure that the correct torque is applied to the inlet pipe nut.
    2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    3. Make sure that the pipe is not deformed or twisted during installation. If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new pipe.

  3. Using SST, tighten the nut at the supply pump end of the fuel inlet pipe.

    SST:

    09023-38401

    Torque:

    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

    HINT:

    1. Use of the proper SST is required to ensure that the correct torque is applied to the inlet pipe nut.
    2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
    3. Make sure that the pipe is not deformed or twisted during installation. If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new pipe.

  4. Tighten the fuel inlet pipe clamp nut.

    Torque:

    5.0 N*m{ 51 kgf*cm , 44 lbsf.in }

4. CONNECT ENGINE WIRE

  1. Connect the engine wire to the engine cover bracket.

  2. Connect the glow plug wire harness.

  3. Install the 2 nuts.

  4. Install the nut and grommet.

    Torque:

    2.2 N*m{ 22 kgf*cm , 19 lbsf.in }

  5. Connect the turbo pressure sensor connector.

  6. Connect the pressure discharge valve connector.

  7. Connect the fuel pressure sensor.

5. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
6. BLEED AIR FROM FUEL SYSTEM

 

Common rail 2AD-FHV, bleed the fuel system.

  1. Using the hand pump indicated by the arrows in the illustration, bleed the fuel system. Continue pumping until pumping becomes difficult.

7. CHECK FOR FUEL LEAKS

 

Common rail 2AD-FHV

  1. Perform the ACTIVE TEST.

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch on (IG).

    3. Turn the intelligent tester ON.

    4. Enter the following menus: Powertrain / Engine / Active Test.

    5. Perform the Active Test.

      Intelligent Tester Display Test Details Control Range Diagnostic Notes
      Test the Fuel Leak Pressurizing common rail internal fuel pressure, and checking for fuel leaks Stop/Start
      1. Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when Start is selected
      2. Above conditions to be maintained while test is Start
8. INSTALL NO. 1 ENGINE COVER

 

Common rail 2AD-FHV. Attach the 4 clips to install the engine cover.

  1. Attach the 4 clips to install the engine cover.

2AD-FHV