Common Rail Installation

Install the common rail with the 2 bolts.

Torque:

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

Connect the fuel pressure sensor connector.

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. If the common rail 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.
   

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

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

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

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

Install the oil dipstick guide with the bolt.

Torque:

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

Install the clamp with the bolt.

Torque:

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

Temporarily install the leakage pipe with the 3 bolts.

Temporarily install a new gasket and the check valve.

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

Connect the 2 fuel hoses.

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

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.

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

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

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

Using union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

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

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

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.
   

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

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

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

Using union nut wrench, tighten the injection pipe union nut on the injector side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

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

Check and clean the oil filter installation surface.

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

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

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.
   

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.

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

Torque:

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

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}

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

Install a new No. 2 air hose and then tighten the 2 hose clamps.

Torque:

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

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

Torque:

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

Connect the diesel turbo IAT sensor connector.

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

Torque:

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

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

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.

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.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and push the intelligent tester main switch on.

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

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.

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

NOTICE:

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

Reconnect the return hose to the common rail.

Install the under cover with the 2 bolts.

Torque:

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

Install the under cover with the 4 bolts.

Torque:

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