COMMON RAIL REMOVAL


  1. REMOVE BATTERY SERVICE HOLE COVER (w/ Sub-Battery)

  2. DISCONNECT BATTERY NEGATIVE CABLE

  3. REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Remove the radiator cap.

    2. Loosen the radiator drain cock plug and a cylinder block drain cock plug. Then drain the coolant.

      A01BC1SE01

  5. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  6. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  7. REMOVE FRONT DOOR SCUFF PLATE RH

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


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

  9. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBMI

      Remove the 2 bolts. Separate the vane pump oil reservoir assembly.

  10. DISCONNECT OIL RETURN HOSE (w/ Inter Cooler)


    1. A01BFPG

      Loosen the clip.

    2. Disconnect the oil return hose from the intake manifold.

  11. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BGWP

      Disconnect the fuel pressure sensor connector.

    2. A01BD88

      Remove the 2 bolts, 2 nuts, and the EGR pipe sub-assembly.

    3. Remove the 2 gaskets.

  12. REMOVE AIR HOSE NO.4


    1. A01BGX6

      Loosen the 2 clamps.

    2. Remove the air hose No.4.

  13. REMOVE ENGINE THROTTLE BODY ASSEMBLY


    1. A01BCMO

      Disconnect the 2 throttle body connectors.

    2. A01BBJH

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

    3. Remove the gasket from intake air connector.

  14. REMOVE ENGINE SERVICE HOLE COVER NO.2


    1. A01BG4E

      Roll up the carpet.

    2. Remove the 3 bolts and the engine service hole cover No.2.

  15. REMOVE INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BDK1

      Remove the bolt, and separate the manifold stay.

    2. Disconnect the vacuum hose from intake air connector.

    3. A01BEP8E01

      Remove the bolt, 2 nuts and the intake air connector assembly.

    4. Remove the 2 gaskets and intake air connector No.2 from the intake air connector.

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Remove the vacuum regulating valve.


      1. A01BHSL

        Remove the 2 vacuum hoses and the vacuum regulating valve connector.

      2. Remove the 2 bolts and the vacuum regulating valve.

    2. Remove the EGR valve assembly with the sensor.


      1. A01BCF1

        Remove the bolt, and separate the manifold stay.

      2. Disconnect the vacuum hose from the intake air connector.

      3. A01BAPE

        Disconnect the intake air temperature sensor connector.

      4. Disconnect the EGR valve position sensor connector.

      5. A01BACYE01

        Remove the bolt, 2 nuts and the intake air connector assembly.

      6. Remove the 2 gaskets and EGR valve assembly from the intake air connector.

  17. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  18. REMOVE INJECTION PIPE

    SST
    09023-12701

    1. Remove the injection pipe.


      1. A01BC89

        Remove the 2 nuts and injection pipe clamp No.3.

      2. A01BFG2

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701

  19. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Using SST, remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  20. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. A01BE3U

      Disconnect 3 fuel hoses from nozzle leakage pipe assembly No.2.

    2. A01BEHR

      Remove the union bolt from nozzle leakage pipe No.2.

    3. A01BCQO

      Remove the 2 bolts and nozzle leakage pipe No.2.

    4. Remove the gasket from nozzle leakage pipe No.2.

  21. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector from the common rail assembly.

    2. Disconnect the fuel hose from the fuel pressure limiter.

    3. A01BC8UE01

      Remove the 2 bolts and common rail assembly.