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ТОПЛИВНАЯ СИСТЕМА ДВИГАТЕЛЯ COMMON RAIL СНЯТИЕ

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Note:

  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Supply pump assembly Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

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    PRECAUTION

    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).

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    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

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    REMOVE EGR COOLER ASSEMBLY

    (Click here)

  4. Click here

    REMOVE WIRING HARNESS CLAMP BRACKET


    1. A003H7Y

      Disconnect the pressure discharge valve connector from the common rail assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  5. Click here

    REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Note:

    After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.


    1. A003BH9E01

      Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

      09245-11010
    2. A003D94

      Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      Note:

      When removing the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

  6. Click here

    REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Table 1. Text in Illustration
    *a Common Rail Assembly Side
    *b Fuel Supply Pump Assembly Side

    1. Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.

    2. A003BZIE01

      Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.

      09245-11010
      Note:

      If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1 or No. 2 injection clamp with a new one.

    3. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump assembly side.

  7. Click here

    REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe (Click here).

      Table 2. Text in Illustration
      A003GWQ Union Bolt
      A003G0E Bolt
      A003AH0 Supply Pump Hollow Screw

    2. Remove the bolt from the intake manifold.

    3. Remove the union bolts and gasket from the supply pump assembly.

    4. Remove the supply pump hollow screw and gasket from the supply pump assembly.

  8. Click here

    REMOVE NO. 4 FUEL HOSE


    1. A003FWE

      Slide the clamp and disconnect the No. 4 fuel hose from the common rail assembly.

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    REMOVE COMMON RAIL ASSEMBLY


    1. A003BFK

      Detach the wire harness clamp.

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

    3. A003F27

      Remove the 2 nuts and common rail assembly.

      Note:

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