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COMMON RAIL (w/o DPF) REMOVAL

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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.

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  1. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    • After turning the ignition 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. Click here

    REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Remove the electric EGR control valve assembly (Click here).

  3. Click here

    DISCONNECT INLET HEATER WATER HOSE (w/o EGR System)


    1. A01DSEF

      Remove the bolt and disconnect the inlet heater water hose.

  4. Click here

    DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)


    1. A01DOGA

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  5. Click here

    REMOVE NO. 1 INTAKE PIPE (w/o EGR System)


    1. A01DN3I

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A01DNIV

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A01DQ50

      Loosen the hose clamp of the intercooler air hose.

    6. A01DMJ4

      Remove the 2 bolts and No. 1 intake pipe.

  6. Click here

    REMOVE THROTTLE BODY BRACKET (w/o EGR System)


    1. A01DS9F

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

  7. Click here

    REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)

    Note:

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

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


    1. A01DNYE

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

    2. A01DTCN

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

    3. A01DRL5E01

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

      Table 1. Text in Illustration
      *a Injector Side
      *b Common Rail Side
  8. Click here

    REMOVE AIR CONNECTOR STAY (w/o EGR System)


    1. A01DQZJ

      Remove the 3 bolts and air connector stay.

  9. Click here

    DISCONNECT ENGINE WIRE (w/o EGR System)


    1. A01DOC8

      for LHD:

      Remove the 2 bolts and disconnect the clamp and engine wire.

    2. A01DOKK

      for RHD:

      Remove the bolt and disconnect the engine wire.

  10. Click here

    REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. A01DO8N

      Disconnect the throttle position sensor connector.

    2. A01DSBE

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  11. Click here

    REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A01DU30

        w/o EGR System:

        Disconnect the connector.

      2. A01DSOX

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A01DU9F

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A01DR0B

      Disconnect the No. 1 vacuum transmitting hose.

    3. A01DUDJ

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A01DNW0

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A01DSHRE03

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

      Table 2. Text in Illustration
      *A w/o EGR System
      *B w/ EGR System
    6. A01DUH7

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  12. Click here

    REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DPTWE01

      Using SST, remove the oil filter.

      09228-07501
  13. Click here

    REMOVE VACUUM CONTROL VALVE SET


    1. A01DPPT

      Disconnect the 2 VSV connectors and 3 vacuum hoses.

    2. Remove the 2 bolts and vacuum control valve set.

  14. Click here

    REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DO5J

      Remove the bolt and detach the injection pipe clamp.

      Note:

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A01DUTCE06

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

      Table 3. Text in Illustration
      *a Injector Side
      *b Common Rail Side
  15. Click here

    REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DNQTE01

      Disconnect the 3 fuel hoses.

    2. Remove the union bolt, 4 bolts, No. 2 nozzle leakage pipe and gasket.

      Table 4. Text in Illustration
      *1 Union Bolt
  16. Click here

    REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01DSQX

      Remove the bolt and clamp.

    2. A01DR6BE02

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

      Table 5. Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side
  17. Click here

    REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector and pressure discharge valve connector.

    2. A01DSDG

      Remove the 2 bolts, common rail and No. 2 intake manifold insulator.

      Note:

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