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. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  2. DRAIN ENGINE COOLANT

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE DIESEL THROTTLE BODY ASSEMBLY

    Click here

  5. REMOVE FRONT DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

  6. REMOVE FRONT SEAT ASSEMBLY RH

    Click here

  7. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet and remove the engine service hole sub cover.

  8. REMOVE COMPRESSOR ELBOW STAY


    1. A01BF8X

      Remove the 2 bolts and compressor elbow stay.

  9. REMOVE COMPRESSOR OUTLET ELBOW


    1. A01BFP8

      Loosen the 2 hose clamps and remove the bolt and compressor outlet elbow.

  10. REMOVE FAN AND GENERATOR V BELT


    1. A01BERGE01

      Remove the drive belt by rotating the tensioner pulley clockwise to loosen its tension with the pulley set bolt of the tensioner.

  11. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A01BGYM

      Remove the bolt and disconnect the cooler refrigerant discharge hose from the compressor and magnetic clutch.

    2. Remove the O-ring from the cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  12. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. A01BDO5

      Remove the bolt and disconnect the cooler refrigerant suction hose.

    2. Remove the O-ring from the cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

  13. REMOVE COMPRESSOR AND MAGNETIC CLUTCH


    1. Disconnect the connector.

    2. A01BFJ0

      Remove the 4 bolts and compressor and magnetic clutch.

  14. DISCONNECT ENGINE WIRE


    1. A01BH3F

      Detach the 3 clamps and disconnect the water by-pass hose and oil return hose.

    2. A01BF0O

      Detach the clamp and disconnect the glow plug connector.

    3. Disconnect the 11 connectors and detach the clamp.

    4. Remove the 7 bolts and disconnect the engine wire.

      A01BEQZ

    5. Disconnect the 4 connectors and detach the 3 clamps.

    6. Remove the terminal cap.

    7. Remove the nut and disconnect the wire harness from terminal B.

    8. Remove the bolt and disconnect the engine wire.

      A01BGIGE01

    9. Fold back the floor carpet.

    10. Disconnect the 6 ECM connectors.

    11. A01BEK4

      Remove the bolt.

    12. A01BCV8

      Disconnect the 3 connectors.

  15. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01BAC9

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

    2. A01BEYL

      Using a 17 mm union nut wrench, loosen the union nuts and remove the 4 injection pipes.

  16. REMOVE VACUUM CONTROL VALVE SET


    1. A01BBW7

      Disconnect the vacuum control valve connector and 2 vacuum hoses.

    2. Remove the bolt and vacuum control valve set.

  17. DISCONNECT NO. 5 WATER BY-PASS HOSE

    A01BEFN

  18. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.


    1. A01BFWK

      Remove the 2 bolts and 2 No. 1 injection pipe clamps.

    2. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  19. REMOVE COMMON RAIL ASSEMBLY


    1. A01BFXR

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.