COMMON RAIL REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, 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

    • 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.

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

  3. REMOVE EGR COOLER ASSEMBLY

    Click here

  4. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

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

    Click here

  6. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  7. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  8. REMOVE NO. 4 FUEL HOSE


    1. B001GUR

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

  9. REMOVE COMMON RAIL ASSEMBLY


    1. B001I9U

      Detach the wire harness clamp.

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

    3. Remove the 2 nuts and common rail assembly.

      Note

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