COMMON RAIL REMOVAL

PROCEDURE


  1. PRECAUTION

    Note


    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A01M29ZN01

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST
      PZ4TB-04941-79

  2. REMOVE INTAKE MANIFOLD

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  3. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  4. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01LVUCC01
      *1 Rubber Grommet
      *2 Rubber Mount

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

      SST
      PZ4TB-04959-10

      Note


      • Be careful not to bend the pressure line with SST.

      • Always reposition SST before it contacts the pressure line.

    2. Using SST, loosen the union nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

      SST
      PZ4TB-04959-10

      Note


      • Be careful not to bend the pressure line with SST.

      • Always reposition SST before it contacts the pressure line.

    3. Remove the fuel inlet pipe sub-assembly from the rubber grommet and rubber mount.

  5. REMOVE COMMON RAIL ASSEMBLY


    1. A01M03S

      Disconnect the fuel pressure sensor connector.

    2. A01M2IH

      Disconnect the pressure discharge valve assembly connector.

    3. A01LZAEC01
      *a Push

      Push at the location shown in the illustration and disconnect the fuel return tube.

    4. A01LV55

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 2 common rail assembly brackets.

    5. Remove the common rail assembly from the cylinder head cover sub-assembly.

  6. REMOVE FUEL PRESSURE SENSOR

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  7. REMOVE PRESSURE DISCHARGE VALVE ASSEMBLY

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