COMMON RAIL REMOVAL


  1. TILT UP CAB

    CAUTION:


    • Make sure that the vehicle is on a level surface before tilting the cab up.

    • Make sure that all the doors are closed before tilting the cab up.

    • Make sure that nobody is inside or near the cab when tilting it up.

    • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

    • Be sure to remove anything set on top of the cab before tilting it up.

    • Make sure that the cab is securely locked in place after it is tilted up.

    • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

    • Make sure that the cab is securely locked in place after tilting it back down.

  2. PRECAUTION

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • Do not allow dirt and water to enter parts.

    • Make sure that there is no dirt at the connections before installing parts.

    • Air enters the fuel pipe when installing the fuel filter case. Thoroughly purge air from the fuel pipe after installation.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  4. REMOVE EGR COOLER SUB-ASSEMBLY

    Click here

  5. REMOVE HARNESS BRACKET


    1. Disconnect each wire harness and clamp.

    2. A01CH1N

      Remove the bolt and harness bracket.

  6. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01CI2D

      Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  7. REMOVE FUEL SUPPORT


    1. A01CIXG

      Remove the 2 bolts and 2 injection pipe clamps.

    2. A01CJ37

      Remove the 2 bolts and fuel support.

  8. DISCONNECT FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


    1. A01CHWY

      Remove the 2 nuts and 2 fuel pipe clamps.

    2. Using a 17 mm union nut wrench, loosen the union nut.

    3. Disconnect the fuel filter to injection pump fuel pipe sub-assembly.

      Note

      Make sure that no foreign matter or water enters the parts during the procedure.

  9. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01CGNQ

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

  10. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector.


      1. A01CGLY

        Pull the connector off of the fuel pressure sensor while pushing down the spring lock of the connector.

        Note

        If the connector is disconnected without the spring lock being pushed down, the connector may be damaged.

    2. A01CJ6J

      Remove the union bolt and gasket.

      Note

      Make sure that no foreign matter or water enters the parts during the procedure.

    3. Disconnect the fuel pipe.

      Note

      Make sure that no foreign matter or water enters the parts during the procedure.

    4. A01CGSB

      Remove the 2 bolts, common rail assembly fuel pipe support and common rail assembly.