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 engine 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

    Click here

  9. DISCONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  11. REMOVE AIR TUBE SUB-ASSEMBLY RH

    Click here

  12. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  13. REMOVE AIR TUBE SUB-ASSEMBLY LH

    Click here

  14. REMOVE NO. 1 GAS FILTER

    Click here

  15. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  16. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  18. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  19. REMOVE INTAKE AIR CONNECTOR

    Click here

  20. REMOVE NO. 1 AIR HOSE

    Click here

  21. REMOVE NO. 3 AIR TUBE

    Click here

  22. REMOVE NO. 2 AIR HOSE

    Click here

  23. REMOVE NO. 4 AIR TUBE

    Click here

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

    Click here

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

    Click here

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

    Click here

  27. DISCONNECT FUEL HOSE

    Click here

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

    Click here

  29. REMOVE NO. 4 WATER BY-PASS PIPE

    Click here

  30. DISCONNECT ENGINE WIRE

    Click here

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

    Click here

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

    Click here

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

    Click here

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

    Click here

  35. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  36. REMOVE INJECTION PIPE LH

    Click here

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


    1. B001A75

      Remove the No. 4 fuel hose.

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

      Note


      • When removing the fuel pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its common rail assembly.

  38. REMOVE NO. 5 NOZZLE LEAKAGE PIPE


    1. w/ DPF:


      1. Disconnect the fuel hose.

      2. B001AWG

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

    2. B001990

      w/o DPF:

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

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its common rail assembly.

  39. REMOVE COMMON RAIL ASSEMBLY LH


    1. B0018QHE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail assembly LH.

      Note


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

      • w/ DPF:

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

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

    Click here

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

    Click here

  42. DISCONNECT FUEL PUMP MOTOR WIRE

    Click here

  43. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  44. REMOVE INJECTION PIPE RH

    Click here

  45. REMOVE COMMON RAIL ASSEMBLY RH


    1. B0019QOE03
      Text in Illustration
      *A w/ DPF
      *B w/o DPF

      Remove the 2 bolts and common rail assembly RH.

      Note

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