COMMON RAIL REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.

  • w/ DPF:

    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

PROCEDURE


  1. 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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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


    1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  7. DRAIN ENGINE COOLANT

    Click here

  8. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  9. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)

    Click here

  10. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  11. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  12. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  13. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  15. DRAIN CLUTCH FLUID (for Manual Transmission)

  16. REMOVE CLUTCH HOSE (for Manual Transmission)

    Click here

  17. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  18. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

    Click here

  19. REMOVE NO. 1 GAS FILTER

    Click here

  20. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  21. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  24. REMOVE INTAKE AIR CONNECTOR

    Click here

  25. REMOVE NO. 3 AIR TUBE

    Click here

  26. REMOVE NO. 2 AIR HOSE

    Click here

  27. REMOVE NO. 4 AIR TUBE

    Click here

  28. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  29. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  30. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  31. DISCONNECT FUEL HOSE

    Click here

  32. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  33. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  34. DISCONNECT ENGINE WIRE

    Click here

  35. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

  36. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

    Click here

  37. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  38. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)

    Click here

  39. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  40. REMOVE INJECTION PIPE LH

    Click here

  41. REMOVE NO. 2 FUEL PIPE (w/ DPF)


    1. B001VP5

      Remove the No. 4 fuel hose.

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

  42. REMOVE NO. 5 NOZZLE LEAKAGE PIPE


    1. w/ DPF:


      1. Disconnect the fuel hose.

      2. B001WVT

        Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

    2. B001Z21

      w/o DPF:

      Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

  43. REMOVE COMMON RAIL ASSEMBLY LH


    1. B001YN1E02
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail.

      Note


      • Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

      • w/ DPF:

        Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

  44. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  45. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)

    Click here

  46. DISCONNECT FUEL PUMP MOTOR WIRE

    Click here

  47. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  48. REMOVE INJECTION PIPE RH

    Click here

  49. REMOVE COMMON RAIL ASSEMBLY RH


    1. B001XMAE02
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail.

      Note

      Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.