COMMON RAIL (w/o DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. DRAIN ENGINE COOLANT

    A01BCB6E01

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator reserve tank 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. Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

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

    4. Tighten the engine drain plug (on the radiator).

    5. Tighten the engine drain plug (on the engine oil cooler cover).

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

  3. REMOVE FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  4. REMOVE FRONT DOOR SCUFF PLATE RH

  5. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the 5 bolts and engine service hole sub cover sub-assembly.

  6. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

    1. Remove the 2 bolts, and separate the vane pump oil reservoir assembly.

  7. DISCONNECT OIL RETURN HOSE

    A01BCQX

    1. Loosen the 2 clips.

    2. Disconnect the oil return hose.

  8. REMOVE EGR COOLER ASSEMBLY

    A01BH3G

    1. Loosen the clip and disconnect the No. 4 water by-pass hose.

    2. Loosen the clip and disconnect the No. 2 water by-pass hose.

    3. A01BDC3

      Remove the 3 bolts and 2 nuts and remove the EGR cooler assembly.

  9. REMOVE NO. 4 AIR HOSE

    A01BGX6

    1. Loosen the 2 clamps.

    2. Remove the No. 4 air hose .

  10. REMOVE INJECTION PIPE

    A01BALH

    1. Disconnect the fuel injector connector and harness clamps.

    2. Remove the 3 bolts.

    3. A01BEJA

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

    4. A01BFN0

      Using SST, remove the 4 injection pipes.

      SST
      09023-12701

  11. REMOVE OIL LEVEL GAUGE GUIDE

    A01BF6Z

    1. Remove the oil level gauge.

    2. Remove the bolt and remove the oil level gauge guide.

  12. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    A01BC23

    1. Remove the 2 clamp bolts.

    2. A01BDF3

      Using SST, loosen the 2 union nuts and remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  13. REMOVE COMMON RAIL ASSEMBLY

    A01BFUS

    1. Disconnect the 2 connectors from the common rail.

    2. Disconnect the fuel hose.

    3. A01BEK0

      Remove the 2 bolts and remove the common rail.