COMMON RAIL REMOVAL

Note


  • Do not use an ohmmeter to check the sensor.

  • Checking the sensor with an ohmmeter could damage the sensor.


  1. REMOVE BATTERY


    1. A01382G

      Disconnect the negative battery cable.

    2. Disconnect the positive battery cable.

    3. Remove the bolt, clamp and battery.

  2. DRAIN ENGINE COOLANT

    Note

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


    1. A01375N

      Remove the drain plug and clip, then drain the engine coolant.

    2. Disconnect the radiator by uncoupling the radiator hose No.2.

    3. A01379O

      Remove the hose clamp, disconnect the water by-pass hose.

    4. Remove the reservoir tank cap sub-assembly.

      A01389E

  3. REMOVE FRONT WIPER HEAD CAP

    A0136ST

    1. Using a screwdriver with its tip wrapped in protective tape, remove the front wiper arm head cap.

  4. REMOVE FRONT WIPER ARM LH


    1. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    2. A013933

      Remove the nut and front wiper main arm.

    3. A0135UZ

      Disengage the meshing of the secondary arm from the front wiper motor and link assembly.

      Note

      Do not bend the secondary arm when removing it.

  5. REMOVE HOOD TO COWL TOP SEAL

    A01379NE01

    1. Disengage the 8 clips and remove the hood to cowl top seal.

  6. REMOVE COWL TOP VENTILATOR LOUVER LH

    A0136GYE01

    1. Remove the clip.

    2. Disengage the 8 claws and remove the cowl top ventilator louver RH.

    3. Disconnect the washer hose.

  7. REMOVE COWL TOP VENTILATOR LOUVER RH

    A0136GYE01

    1. Remove the clip.

    2. Disengage the 8 claws and remove the cowl top ventilator louver RH.

    3. Disconnect the washer hose.

  8. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    A0136OQ

    1. Remove the 2 bolts.

    2. Disconnect the connector and remove the front wiper motor and link assembly.

  9. REMOVE COWL TOP PANEL OUTER


    1. A0136J7

      Remove the 10 bolts and cowl top panel outer.

  10. REMOVE ENGINE COVER


    1. A0138OOE01

      Disengage the 3 claws and remove the engine cover.

  11. REMOVE AIR CLEANER CAP


    1. A0136JLE01

      Using a "torx" socket wrench, loosen the 3 screws, and remove the air cleaner cap.

  12. REMOVE AIR HOSE


    1. A0137HDE03

      Loosen the clamp bolt.

    2. Using a screwdriver and pliers, remove the clip.

    3. Remove the air hose.

  13. REMOVE MASS AIR FLOW METER


    1. Disconnect the mass air flow meter connector.

    2. A0136T5

      Using a "torx" socket wrench, remove the 2 screws and the mass air flow meter.

    3. Remove the O-ring from the mass air flow meter.

  14. SEPARATE ENGINE ROOM RELAY BLOCK


    1. A013706

      Remove the 2 bolts and disengage the claw.

    2. Separate the 3 wire harness clamps and the engine room relay block.

  15. REMOVE INLET AIR CLEANER


    1. A0137J3

      Remove the inlet air cleaner.

  16. REMOVE INLET AIR CLEANER NO.2


    1. A0135TK

      Using a "torx" socket wrench, remove the screw.

    2. A0137CO

      Turn the inlet air cleaner No.2.

    3. Remove the inlet air cleaner No.2.

  17. REMOVE TURBO PRESSURE SENSOR


    1. A0136NOE01

      Disconnect the turbo pressure sensor connector.

    2. Remove the screw and disconnect the hose to remove the turbo pressure sensor.

  18. REMOVE PRIMING PUMP BRACKET


    1. A0136D2

      Separate the priming pump bracket from the air cleaner case.

    2. A01386D

      Remove the priming pump bracket.

  19. REMOVE AIR CLEANER CASE


    1. A0138CME01

      Using a "torx" socket wrench, loosen the 2 screws.

    2. A0137NFE01

      Remove the 2 wire harness clamps and the air cleaner case.

  20. DISCONNECT VACUUM HOSE ASSEMBLY


    1. A0137N5

      Pinch the retainer as illustrated, then pull out the vacuum hose connector from the pipe.

  21. DISCONNECT FUEL HOSE


    1. A0136VFE01

      Pinch the tube connector and then pull out the fuel hose.

      Note


      • Check if there is any dirt or other foreign objects around the connector before this operation and clean the connector as necessary.

      • Remove the quick connector by hand.

      • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.

      • If the pipe and the connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully.

  22. REMOVE FUEL FILTER PROTECTOR


    1. A0137JM

      Using a "torx" socket wrench, remove the 2 screws and the fuel filter protector.

  23. REMOVE FUEL FILTER


    1. A0135V6E01

      Pinch the 2 tube connectors and then pull out the 2 fuel hoses.

      Note


      • Check if there is any dirt or other foreign objects around the connectors before this operation and clean the connectors as necessary.

      • Remove the quick connectors by hand.

      • Do not bend or twist the nylon tubes. Protect the connectors by covering them with plastic bags.

      • If the pipe and the connector are stuck, try wiggling or pushing and pulling the connector to release it and pull the connector off of the pipe carefully.

    2. A0138SCE01

      Using a "torx" socket wrench, remove the screw.

    3. For LHD:


      1. Disconnect the fuel filter warning switch connector.

    4. Disconnect the fuel heater connector and remove the fuel filter.

  24. DISCONNECT WIRE HARNESS


    1. A0137RYE01

      Pull up the lock and disconnect the connector.

    2. A0136H4

      Disconnect the injector connectors.

  25. REMOVE FUEL FILTER BRACKET


    1. A0136F4

      Using a "torx" socket wrench, remove the screw.

    2. Remove the 2 bolts and the fuel filter bracket.

  26. REMOVE INTAKE AIR RESONATOR


    1. A01390W

      Disconnect and remove the water reservoir tube from the intake air resonator.

    2. A0138YRE02

      Disconnect the turbocharger air temperature sensor connector and loosen the clamp.

    3. Remove the bolt.

    4. Using a "torx" socket wrench, remove the screw.

    5. A0135Z7E02

      Turn the intake air resonator, and remove the intake air resonator as shown in the illustration.

    6. Remove the O-ring from the intake air resonator.

  27. REMOVE THROTTLE VALVE (FOR EGR)


    1. A0135W6

      Remove the throttle valve connector.

    2. A0135U9

      Using a "torx" socket wrench, remove the 3 screws and the throttle valve.

    3. Remove the O-ring from the throttle valve.

  28. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01375Q

      Separate the wire harness clamp.

    2. A0136D4

      Remove the bolt and wire harness clamp bracket.

  29. DISCONNECT HEATER HOSE


    1. A0138V1

      Remove the hose clip.

    2. Disconnect the heater hose.

  30. DISCONNECT WATER BY-PASS HOSE


    1. A0136KM

      Remove the hose clamp.

    2. Disconnect the EGR cooler water by-pass hose.

  31. DISCONNECT WATER HOSE


    1. Check for dirt in the pipe around the connector before disconnecting. Clean away the dirt as necessary.

    2. A0136O3E01

      Be sure to disconnect the connectors by hand.

    3. When the connector and the pipe are stuck, pinch the fuel pipe with the fingers, and push and pull the connector. Disconnect and pull the connector out of the pipe. Do not use any tools.

    4. Check for dirt or other foreign objects on the surface of the seal on the disconnected pipe and clean as necessary.

  32. DISCONNECT ECM CONNECTOR


    1. A0137UFE01

      Press the lock and turn the retainers as shown in the illustration.

      Note


      • Check the ECM and the area around the ECM for water or dirt. Clean them as necessary.

      • Check the connection of the removed ECM connector for water or dirt. Clean it as necessary.

    2. A0137ONE01

      Disconnect the 3 ECM connectors.

  33. REMOVE EGR VALVE ASSEMBLY W/ EGR COOLER


    1. Disconnect the EGR valve connector.

    2. A01367WE01

      Using a "torx" socket wrench, remove the 2 screws.

    3. Remove the 2 bolts and EGR valve assembly w/ EGR cooler.

    4. Remove the EGR valve gasket from the cylinder head.

  34. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY


    1. A01367O

      Remove the 2 clips and disconnect the 2 water by-pass hoses from the reserve tank.

    2. A0135ZD

      Remove the clip and disconnect the water by-pass hose No.5.

    3. A0136BI

      Remove the bolt and radiator reserve tank.

  35. SEPARATE WIRE HARNESS AND CONNECTOR


    1. Disconnect the camshaft position sensor connector.

    2. A0135ZI

      Separate the 4 clamps of the wire harness.

    3. A01372G

      Separate the clamp of the wire harness.

    4. A0136O1

      Remove the wire harness clamp.

  36. REMOVE TIMING BELT UPPER COVER


    1. A0136LB

      Remove the 5 bolts and the timing belt cover sub-assembly.

  37. SEPARATE FUEL TEMPERATURE SENSOR


    1. A0135X2

      Disconnect the tube and separate the fuel temperature sensor from the cylinder head cover sub-assembly.

  38. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0136DX

      Remove the 10 bolts and the cylinder head cover sub-assembly and gasket.

    2. Remove the 4 O-rings from the cylinder head cover sub-assembly.

  39. REMOVE INJECTION PIPE

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the pipe, put it in a plastic bag to prevent foreign matter from entering the injector inlet.


    1. A0138D9E01

      Using SST, loosen the 4 union nuts (injector end).

      SST
      09023-38401

      Note

      While holding the union on each injector using a wrench, loosen the union nut on the injection pipe.

    2. A0136SBE01

      Using SST, loosen the union nut (supply pump end).

      SST
      09023-38401

      Note

      While holding the union on supply pump using a wrench, loosen the union nut on the injection pipe.

    3. A0138BZE01

      Using SST, loosen the 5 union nuts (common rail side) and remove the injection pipes.

      SST
      09023-12701

  40. REMOVE COMMON RAIL ASSEMBLY


    1. A0135SW

      Remove the bolt and separate the water outlet box support.

    2. A0138TY

      Disconnect the fuel pressure sensor connector.

    3. A013887

      Remove the 2 bolts and common rail assembly from the cylinder block.