FUEL.pdf

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11–76
FUEL
–
COMMON RAIL ASSY (1CD–FTV)
COMMON RAIL ASSY (1CD–FTV)
110UB–01
COMPONENTS
Clip
Ratainer
8.0 (82, 71 in.Vlbf)
Radiator Support Opening Cover
Engine Cover No. 1
6.0 (61, 53 in.Vlbf)
Radiator Reserve
Tank Assy
N·m (kgf·cm, ft·lbf) : Specified torque
A79437
AVENSIS REPAIR MANUAL (RM1018E)
11–77
FUEL
–
COMMON RAIL ASSY (1CD–FTV)
* 31 (316, 23)
34 (347, 25)
5.0 (51, 44 in.Vlbf)
Injection Pipe Clamp No. 2
z
Fuel Inlet Pipe Sub–assy
* 31 (316, 23)
34 (347, 25)
z
Injection Pipe Sub–assy
* 31 (316, 23)
34 (347, 25)
Common Rail Assy
Intake Manifold
Insulator No. 1
5.0 (51, 44 in.Vlbf)
43 (438, 32)
Fuel Hose No. 4
N·m (kgf·cm, ft·lbf) : Specified torque
z
Non–reusable part
* Use SST
AVENSIS REPAIR MANUAL (RM1018E)
A79438
11–78
FUEL
–
COMMON RAIL ASSY (1CD–FTV)
110UC–01
REPLACEMENT
1.
2.
3.
(a)
4.
DRAIN ENGINE COOLANT (See
page 16–44)
REMOVE RADIATOR SUPPORT OPENING COVER
REMOVE ENGINE COVER NO.1
Remove the 5 nuts and the engine cover.
REMOVE RADIATOR RESERVE TANK ASSY (See
page 16–50)
SST
A79148
5.
REMOVE FUEL INLET PIPE SUB–ASSY
NOTICE:
After removing the fuel inlet pipe, cover the common rail
and the injection pump with vinyl tape to prevent dust from
being introduced.
(a) Using SST, remove the fuel inlet pipe from the common
rail.
SST 09023–12700
(b) Using SST, remove the fuel inlet pipe from the injection
pump.
SST 09023–12700
6.
(a)
(b)
SST
(c)
A79143
(d)
7.
REMOVE INJECTION PIPE SUB–ASSY
SST 09023–12700
REMOVE INJECTION PIPE SUB–ASSY NO.1
Remove the 2 nuts and the 2 upper infection pipe clamps
from the intake manifold.
Using SST, remove the injection pipe from the common
rail side.
SST 09023–12700
Using SST, remove the injection pipe from the injector
side.
SST 09023–12700
After removing the fuel pipe, to prevent dust or foreign ob-
jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or plas-
tic bag.
NO.2
HINT:
Perform the same procedures as injection pipe No. 1.
8.
REMOVE INJECTION PIPE SUB–ASSY NO.3
SST 09023–12700
HINT:
Perform the same procedures as injection pipe No. 1.
AVENSIS REPAIR MANUAL (RM1018E)
11–79
FUEL
–
COMMON RAIL ASSY (1CD–FTV)
9.
REMOVE INJECTION PIPE SUB–ASSY NO.4
SST 09023–12700
HINT:
Perform the same procedures as injection pipe No. 1.
10. DISCONNECT FUEL HOSE NO.4
(a) Disconnect the fuel hose from the common rail.
11. REMOVE INTAKE MANIFOLD INSULATOR NO.1 (See
page 11–69)
12.
(a)
(b)
REMOVE COMMON RAIL ASSY
Disconnect the engine wire connector from the bracket.
Remove the 2 bolts and the common rail.
A79154
13.
14.
INSTALL COMMON RAIL ASSY
Torque: 43 NVm (438 kgfVcm, 32 ftVlbf)
INSTALL INTAKE MANIFOLD INSULATOR NO.1 (See
page 11–69)
30 cm
(11.81 in.)
SST
A79147
15. INSTALL INJECTION PIPE SUB–ASSY NO.1
NOTICE:
S
In case of having the common rail replaced, must re-
place the injection pipes, too.
S
When assembling the pipes, perform the operation
with the engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and
vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
AVENSIS REPAIR MANUAL (RM1018E)
11–80
FUEL
–
COMMON RAIL ASSY (1CD–FTV)
(c)
Using SST, tighten the nut of the injection pipe to the com-
mon rail side.
SST 09023–12700
Torque:
42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST
46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using
SST
31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST
34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using
SST
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
Using SST, tighten the nut of the injection pipe to the injec-
tor side.
SST 09023–12700
Torque:
42 NVm (428 kgfVcm, 31 ftVlbf) for a used pipe using SST
46 NVm (469 kgfVcm, 34 ftVlbf) for a used pipe not using
SST
31 NVm (316 kgfVcm, 23 ftVlbf) for a new pipe using SST
34 NVm (347 kgfVcm, 25 ftVlbf) for a new pipe not using
SST
HINT:
S
S
(d)
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
S
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e) Install the 2 upper injection pipe clamps with the 2 nuts.
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
INSTALL INJECTION PIPE SUB–ASSY NO.2
SST 09023–12700
S
16.
HINT:
Perform the same procedures as injection pipe No. 1.
17. INSTALL INJECTION PIPE SUB–ASSY NO.3
SST 09023–12700
HINT:
Perform the same procedures as injection pipe No. 1.
18. INSTALL INJECTION PIPE SUB–ASSY NO.4
SST 09023–12700
HINT:
Perform the same procedures as injection pipe No. 1.
AVENSIS REPAIR MANUAL (RM1018E)

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