2.
Disconnect the rail pressure sensor connector (A).
Common Rail Fuel Injection System operates with extremely high pressure (approximately 2,000bar), so do not perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep clean the components of common rail system and the working area.
Be careful the influx of foreign substance when installing the fuel supply system.
Remove the protect-cap attaced in the injector, tube or hose etc. to prevent the influx of a foreign substnace just before installing them.
Do not remove injector except for special case.
When installing the injector
- Clean the contact area of the injector and replace the gasket with a new one.
- Vertically insert the injector into the cylinder head to prevent the damage caused by shock.
- Clean the surface under the injector gasket of the cylinder head before installing the injector.
When installing High Pressure Fuel Pipe
- Install the flange nut correctly.
- Do not use again the used high pressure fuel pipe. Always use a new one.
When removing / installing the injector return line
- Insert the connector only in the unlock status.
- Insert the connector with hands. Do not use a tool.
Turn ignition switch OFF and disconnect the battery negative (-) battery terminal.
Disconnect the rail pressure sensor connector (A).
Disconnect the fuel return line (A) from the injector.
Disconnect the high pressure fuel pipe flange nut (B) after loosening the clamp mounting bolt (A).
High pressure fuel pipe clamp mounting bolt:
6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
High pressure fuel pipe flange nut:
24.5 ~ 28.4 N.m (2.5 ~ 2.9 kgf.m, 18.1 ~ 21.0 lb-ft)
Remove the high pressure fuel pipe.
Remove the intank Intake Manifold.
(Refer to Engine Mechanical System -"Intake Manifold")
Remove the common rail after loosening the mounting bolts (A).
Common rail mounting bolt:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lb-ft)
Installation is reverse of removal.
When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool (SST No.:09314-27120).
After removing or replacing the part below, bleed air in low pressure fuel circuit.
(Refer to "Bleeding air in low pressure fuel circuit" in this group.)
Fuel tank
Fuel sender
Fuel filter
High pressure fuel pump
Low pressure fuel lines
After removing or replacing fuel system below, must perform fuel leakage test procedure. (Refer to "Fuel leak test" in this group.)
Fuel tank
Fuel sender
Fuel filter
High pressure fuel pump
Injector
Common rail
Low pressure fuel line
