COMMON RAIL REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE


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


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

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

    Click here

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

    Click here

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

    Click here

  6. REMOVE THROTTLE BODY BRACKET (w/o EGR System)

    Click here

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

    Click here

  8. REMOVE AIR CONNECTOR STAY (w/o EGR System)

    Click here

  9. DISCONNECT ENGINE WIRE (w/o EGR System)

    Click here

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

    Click here

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE

    Click here

  12. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  13. REMOVE VACUUM CONTROL VALVE SET

    Click here

  14. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B001F2UE02
      Text in Illustration
      *1 Union Bolt

      Disconnect the 3 fuel hoses.

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

  16. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  17. REMOVE COMMON RAIL ASSEMBLY


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

    2. B001I0Q

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

      Note

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