COMMON RAIL (w/o DPF) REMOVAL

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.


  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)


    1. A00JUQI

      Remove the bolt and disconnect the inlet heater water hose.

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


    1. A00JWMM

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

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


    1. A00JZLQ

      Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

    2. Detach the 2 clamps.

    3. Disconnect the vacuum hose from the manifold absolute pressure sensor.

    4. A00JWSR

      Loosen the 2 hose clamps of the No. 1 air hose.

    5. A00JV3H

      Loosen the hose clamp of the intercooler air hose.

    6. A00K23L

      Remove the 2 bolts and No. 1 intake pipe.

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


    1. A00OA28

      Disconnect the vacuum hose.

    2. Remove the bolt and gas filter with gas filter bracket.

    3. Remove the 2 bolts and throttle body bracket.

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

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. A00XH0D

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. A00XH1Z

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. A00XJETE01
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

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


    1. A00O30T

      Remove the 3 bolts and air connector stay.

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


    1. A00O8HT

      for LHD:

      Remove the 2 bolts and disconnect the clamp and engine wire.

    2. A00OA2U

      for RHD:

      Remove the bolt and disconnect the engine wire.

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


    1. A00O7OP

      Disconnect the throttle position sensor connector.

    2. A00O5VW

      Remove the 3 bolts, intake air connector with diesel throttle and gasket.

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. Disconnect the vacuum switching valve connector.


      1. A00O5P2

        w/o EGR System:

        Disconnect the connector.

      2. A00O70W

        w/ EGR System without EGR Cooler:

        Disconnect the 2 connectors.

      3. A00O5WE

        w/ EGR System with EGR Cooler:

        Disconnect the 3 connectors.

    2. A00O3VL

      Disconnect the No. 1 vacuum transmitting hose.

    3. A00OB6W

      w/ EGR System:

      Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

    4. A00OAHN

      w/ EGR Cooler:

      Disconnect the No. 3 vacuum transmitting hose.

    5. A00O4FYE03
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System

      Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

    6. A00O5B8

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  12. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00JZXEE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  13. REMOVE VACUUM CONTROL VALVE SET


    1. A00O7ZB

      Disconnect the 2 VSV connectors and 3 vacuum hoses.

    2. Remove the 2 bolts and vacuum control valve set.

  14. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XF0Y

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. A00XHHME06
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00O7AGE01
      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


    1. A00O6OB

      Remove the bolt and clamp.

    2. A00O9XIE02
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  17. REMOVE COMMON RAIL ASSEMBLY


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

    2. A00O9DU

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

      Note

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