COMMON RAIL (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DRAIN ENGINE COOLANT

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  2. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  3. SEPARATE ENGINE WIRE


    1. A01KEV0

      Disengage the wire harness clamp, separate the glow plug connector.

    2. Disconnect the 10 connectors.

      A01KG4T

    3. Remove the 4 bolts.

    4. Disengage the 4 wire harness clamps, separate the engine wire.

  4. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01KFWX

      Remove the 3 bolts and 3 No. 2 injection pipe clamps.

    2. A01KF34

      Using a union nut wrench 17 mm, remove the No. 1 to No. 4 injection pipe sub-assembly.

  5. REMOVE NO. 3 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01KF08

      Disconnect the 2 vacuum hoses and No. 3 vacuum switching valve assembly connector.

    2. Remove the bolt and No. 3 vacuum switching valve assembly.

  6. DISCONNECT NO. 5 WATER BY-PASS HOSE


    1. A01KEDI

      Disconnect the No. 5 water by-pass hose.

  7. REMOVE INLET FUEL PIPE SUB-ASSEMBLY


    1. A01KFQN

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

    2. Remove the 2 bolts and inlet fuel pipe sub-assembly.

  8. REMOVE COMMON RAIL ASSEMBLY


    1. A01KI78

      Remove the 2 bolts and common rail assembly.