COMMON RAIL (w/ DPF) REMOVAL

Note


  • When replacing the injector assemblies (including shuffling the injector assemblies between the cylinders), common rail assembly or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.

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

  • After removing the injection pipe sub-assemblies and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  4. DISCONNECT WIRE HARNESS


    1. A01DU9L

      Remove the bolt and disconnect the wire harness.

    2. A01DOMZ

      for LHD:

      Remove the bolt and disconnect the wire harness.

    3. Detach the 5 clamps and disconnect the wire harness from the cowl top panel.

  5. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A01DUFS

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  6. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A01DQAM

      Remove the bolt and emission control valve bracket.

  7. REMOVE THROTTLE BODY BRACKET


    1. A01DPGW

      Remove the 3 bolts and throttle body bracket.

  8. REMOVE NO. 1 GAS FILTER


    1. A01DP2T

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  9. REMOVE GAS FILTER BRACKET


    1. A01DMQK

      Detach the clamp and disconnect the wire harness.

    2. A01DSGE

      Remove the bolt and gas filter bracket.

  10. REMOVE INTAKE AIR CONNECTOR


    1. A01DSTL

      Remove the 3 bolts, intake air connector and gasket.

  11. REMOVE NO. 1 FUEL PIPE


    1. Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

      A01DTAKE01
      Text in Illustration
      *1 No. 2 Fuel Pipe - -
      A01DMKT Union Bolt - -

  12. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DSLU

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01DP3CE01
      Text in Illustration
      *a Common Rail Assembly Side
      *b Injector Assembly Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe sub-assembly.

  13. REMOVE NO. 2 FUEL PIPE


    1. A01DTYW

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A01DQPB Union Bolt
      A01DMKT Fuel Check Valve
      A01DPHJ Bolt

    2. Remove the fuel check valve and gasket.

    3. Remove the bolt and No. 2 fuel pipe.

  14. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DPHI

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A01DMKT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DS6P

      Remove the 2 bolts.

      Text in Illustration
      A01DMKT Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe assembly.

  16. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the 2 vacuum switching valve connectors.

    2. A01DMFA

      Disconnect the 3 vacuum hoses, and then remove the 2 bolts and vacuum control valve set.

  17. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DPTWE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  18. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the pressure discharge valve connector.

    2. A01DMXK

      Remove the 2 bolts and common rail assembly.

      Note

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