2.
Disconnect the control wiring connectors, harness clamps and remove the wiring protector around the intake manifold.
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 control wiring connectors, harness clamps and remove the wiring protector around the intake manifold.
Remove the oil level gauge & guide.
(Refer to Engine Mechanical System - "Oil Level Gauge & Pipe")
Disconnect the fuel return line (A).
Remove the high pressure fuel pipe flange nut (A) after loosening the clamp mounting bolt (B).
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 low pressure fuel feed & return line bracket (B) after loosening the mounting bolt (A).
Low pressure fuel feed & return line bracket mounting bolt :
6.8 ~ 10.7 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
Disconnect the fuel pressure control valve connector (A), fuel feed tube quick-connector (B) and fuel return tube quick-connector ( C).
Remove the intake manifold.
(Refer to Engine Mechanical System - "Intake Manifold")
Lift the vehicle.
Remove the engine room under cover (A).
Remove the drive belt.
(Refer to Engine Mechanical System - "Drive Belt")
Remove the starter.
(Refer to Engine Electrical System - "Starter" )
Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder compression TDC position)
Install the fixing flywheel stopper [SST No: 09231-2B100] on the flywheel.
Lift the RH side of the engine with a jack (A).
Disconnect the ground line (A).
Remove the engine mounting support bracket (A) after loosening the mounting bolt and nuts.
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
Remove the idler (B) using the wrench (A).
Remove the timing chain cover plug (B) using the wrench (A).
Timing chain cover plug :
25.5 ~ 34.3 N.m (2.6 ~ 3.5 kgf.m, 18.8 ~ 25.3 lb-ft)
Remove the high pressure fuel pump sprocket nut (A).
High pressure fuel pump sprocket nut:
64.7 ~ 74.5 N.m (6.6 ~ 7.6 kgf.m, 47.7 ~ 55.0 lb-ft)
Remove the timing chain cover mounting bolts (A).
Fix the high pressure fuel pump remover and stopper (A) [SST No.: 09331-2A010] after lift the RH side of the engine with a jack.
Remove the high pressure fuel pump mounting bolts (A).
High fuel pump mounting bolt:
19.6 ~ 25.5 N.m (2.0 ~ 2.6 kgf.m, 14.5 ~ 18.8 lb-ft)
Install the high pressure fuel pump mounting bolt (A) [SST No.: 09331-2A010]
Rotate the bolt (A) of the high pressure fuel pump remover [SST No.:09331-2A010] clockwise till the high pressure fuel pump is pushed out.
Remove the high pressure fuel pump (A).
Install in the reverse order 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 Fuel Delivery System - "Bleeding air in low pressure fuel circuit")
Fuel Tank
Low Pressure Fuel Pump
Fuel Pump Motor
Fuel Sender
Fuel Filter
Fuel Heater
Water Sensor
Fuel Line
High Pressure Fuel Pump
Common Rail
After removing or replacing fuel system below, must perform fuel leakage test procedure. (Refer to "Fuel leak test" in this group.)
Fuel Tank
Low Pressure Fuel Pump
Fuel Pump Motor
Fuel Sender
Fuel Filter
Fuel Heater
Water Sensor
Fuel Line
High Pressure Fuel Pump
Common Rail
If it is difficult to use the special service tools 09314-27110 or 09314-27120 for tightening some of the high pressure fuel pipe flange nuts to the specified torque, you can use a spanner torque wrench as shown below.
