COMMON RAIL REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. 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 }

  3. REMOVE INTAKE AIR PIPE NO. 1 WITH AIR HOSE NO. 4


    1. A01CIMYE01

      Disconnect the hose band.

    2. A01CGQKE01

      Remove the 2 bolts and bracket.

    3. A01CHLBE01

      Disconnect the turbo pressure sensor connector and wire harness clamp, and remove the bolt.

    4. A01CHYE

      Disconnect the intake air temperature sensor connector, and remove the bolt.

    5. A01CILLE01

      Disconnect the hose band, and remove the No. 1 intake air pipe with No. 4 air hose.

  4. REMOVE DIESEL THROTTLE BODY


    1. A01CIXR

      Disconnect the 2 diesel throttle body connectors.

    2. A01CH6X

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

  5. SEPARATE WIRE HARNESS AND CONNECTORS


    1. A01CH2B

      Disconnect the 3 connectors.

  6. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ16

      Disconnect the hoses from the EGR valve assembly.

    2. A01CJ9R

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

  7. REMOVE EGR COOLER SUB-ASSEMBLY


    1. Separate the water by-pass hose.

    2. Remove the 6 bolts and remove the EGR cooler.

  8. REMOVE VENTILATION PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts.

    2. Disconnect the 3 hoses and remove the ventilation pipe sub-assembly.

  9. REMOVE EGR VALVE BRACKET


    1. A01CIJH

      Remove the 4 bolts and bracket.

  10. REMOVE OIL SEPARATOR ASSEMBLY


    1. A01CGWZ

      Move the clamp and disconnect the hose.

    2. Remove the 2 bolts and the oil separator assembly.

  11. REMOVE VENTURI ASSEMBLY


    1. A01CJ90

      Remove the 4 bolts and the intake pipe with EGR valve.

  12. REMOVE INJECTION PIPE CLAMP


    1. A01CHFZ

      Remove the 2 nuts, oil level dipstick guide and the 2 pipe clamps.

  13. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01CI23

      Using SST, loosen the union nuts and remove the 4 injection pipe sub-assemblies.

      SST
      09023-12901

  14. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01CJ4U

      Remove the 2 union bolts, the 4 gaskets and the No. 4 fuel pipe sub-assembly.

  15. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJ7V

      Remove the nut and the fuel pipe clamp.

    2. Using SST, loosen the union nuts and remove the fuel filter to injection pump fuel pipe.

      SST
      09023-12901

  16. REMOVE COMMON RAIL ASSEMBLY


    1. A01CIBY

      Disconnect the fuel pressure sensor connector.

    2. Remove the 2 bolts, the No. 3 injection pipe bracket and the common rail assembly.