COMMON RAIL REMOVAL


  1. REMOVE ENGINE UNDER COVER

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01CIF0E01

      Loosen the radiator drain cock plug and engine drain plug.

    2. Remove the radiator cap, then drain the coolant.

    3. Close the radiator drain cock plug.

    4. Tighten the engine drain plug.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf, for the engine drain plug }

  4. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01CJ11E01

      Set the No. 1 cylinder to TDC/compression.

      Tech Tips

      Make sure that there is free play in the No. 1 cylinder rocker arms and that there is no free play in the No. 4 cylinder rocker arms.

  5. REMOVE NO. 2 INTAKE PIPE


    1. A01CHOY

      Remove the 3 bolts, loosen the 2 bands, and remove the No. 2 intake pipe.

  6. REMOVE NO. 1 AIR HOSE


    1. A01CIUN

      Remove the 2 bolts and hose clamp, and then remove the No. 1 air hose.

  7. REMOVE NO. 4 AIR HOSE


    1. A01CJ8A

      Loosen the 2 clamps and remove the No. 4 air hose.

  8. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Separate the water by-pass hose.

    2. Remove the 6 bolts and EGR cooler.

  9. SEPARATE WIRE HARNESS AND CONNECTORS


    1. A01CJDO

      Disconnect the 3 connectors, 3 connector clamps and bolt.

  10. REMOVE EGR VALVE BRACKET


    1. A01CISY

      Remove the 4 bolts and bracket.

  11. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ16

      Disconnect the hoses from the EGR valve assembly.

    2. A01CJ9R

      Remove the 3 bolts, 2 union bolts, and 4 gaskets and separate the water by-pass pipe sub-assembly.

  12. REMOVE DIESEL THROTTLE BODY


    1. A01CHFJ

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH93

      Remove the 2 bolts, 2 nuts and diesel throttle body.

  13. REMOVE VENTURI ASSEMBLY


    1. Remove the 4 bolts, 2 nuts and venturi from the intake manifold.

  14. REMOVE INJECTION PIPE CLAMP


    1. A01CJ0C

      Remove the 2 nuts.

    2. Remove the oil level gauge guide and O-ring, and then remove the 2 injection pipe clamps.

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01CHN3

      Using a union nut wrench (17 mm), loosen the 8 union nuts and remove the injection pipe sub-assembly.

  16. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. Separate the wire harness connector.

    2. A01CHXB

      Separate the 2 wire harness clamps.

    3. A01CJB8

      Remove the nut and fuel pipe clamp.

    4. Using a union nut wrench (17 mm), loosen the 2 union nuts.

    5. Remove the fuel filter to injection pump fuel pipe.

  17. REMOVE COMMON RAIL ASSEMBLY


    1. A01CIXW

      Separate the fuel pressure sensor connector.

    2. Loosen the clip and separate the fuel hose.

    3. Remove the 2 bolts and the common rail assembly.