COMMON RAIL(w/ DPF)

REMOVE NO. 1 ENGINE COVER

REMOVE NO. 1 AIR CLEANER HOSE

REMOVE NO. 1 GLOW PLUG CONNECTOR

REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

Note

Perform installation and removal procedures by hand only. Do not use any tools.

Slide the hose clip and disconnect the nozzle leakage pipe assembly from the No. 2 nozzle leakage pipe.

Text in Illustration
*1	Lock Bush	-	-
	Pull Up	-	-

Disengage the clamp to separate the nozzle leakage pipe assembly from the hose clamp.
Pull up the 4 lock bushes of the nozzle leakage pipe assembly as shown in the illustration, and remove it from each injector assembly.

REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 1 injection pipe sub-assembly from the injector assembly and common rail assembly.

Note

To prevent contamination by foreign matter, after removing the No. 1 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 2 injection pipe sub-assembly from the injector assembly and common rail assembly.

Note

To prevent contamination by foreign matter, after removing the No. 2 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

Disconnect the vacuum hose from the No. 2 EGR valve assembly.
Remove the bolt and separate the vacuum transmitting pipe sub-assembly from the EGR cooler bracket.
Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 3 injection pipe sub-assembly from the injector assembly and common rail assembly.

Note

To prevent contamination by foreign matter, after removing the No. 3 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

REMOVE FUEL INLET PIPE SUB-ASSEMBLY

Remove the bolt and No. 3 engine cover bracket from the EGR cooler bracket.
Remove the bolt and No. 2 injection pipe clamp from the fuel inlet pipe sub-assembly and No. 4 injection pipe sub-assembly.
Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the fuel inlet pipe sub-assembly from the injection or supply pump assembly and common rail assembly.

Note

To prevent contamination by foreign matter, after removing the fuel inlet pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

Using a union nut wrench 17 mm, loosen the 2 union nuts in the order shown in the illustration, and remove the No. 4 injection pipe sub-assembly from the injector assembly and common rail assembly.

Note

To prevent contamination by foreign matter, after removing the No. 4 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

REMOVE COMMON RAIL ASSEMBLY

Disconnect the rail pressure sensor connector.
Disconnect the pressure control valve connector.
Slide the hose clip and disconnect the No. 2 fuel hose from the common rail assembly.
Remove the 2 bolts.
Disengage the clamp, and while disconnecting the No. 4 water by-pass hose, remove the common rail assembly from the cylinder head sub-assembly.
Disengage the clamp to remove the hose clamp from the common rail assembly.

COMMON RAIL(w/ DPF) REMOVAL