COMMON RAIL (w/ 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 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.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  4. DISCONNECT WIRE HARNESS


    1. A00JYTX

      Remove the bolt and disconnect the wire harness.

    2. A00K074

      for LHD:

      Remove the bolt and disconnect the wire harness.

    3. Detach the 5 clamps and disconnect the wire harness from the cowl top panel.

  5. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A00JZBI

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  6. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A00JW2S

      Remove the bolt and emission control valve bracket.

  7. REMOVE THROTTLE BODY BRACKET


    1. A00K044

      Remove the 3 bolts and throttle body bracket.

  8. REMOVE NO. 1 GAS FILTER


    1. A00JZLL

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  9. REMOVE GAS FILTER BRACKET


    1. A00K1HA

      Detach the clamp and disconnect the wire harness.

    2. A00K059

      Remove the bolt and gas filter bracket.

  10. REMOVE INTAKE AIR CONNECTOR


    1. A00JWYM

      Remove the 3 bolts, intake air connector and gasket.

  11. REMOVE NO. 1 FUEL PIPE


    1. Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

      A00XH74E01
      Text in Illustration
      *1 No. 2 Fuel Pipe - -
      A00XFQT Union Bolt - -

  12. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XCX9

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A00XCYIE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

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

  13. REMOVE NO. 2 FUEL PIPE


    1. A00XIX4

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A00XHOQ Union Bolt
      A00XFQT Fuel Check Valve

    2. Remove the fuel check valve, gasket and No. 2 fuel pipe.

  14. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A00XGZK

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A00XFQT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00XET4

      Remove the 3 bolts.

      Text in Illustration
      A00XFQT Union Bolt

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

  16. REMOVE VACUUM CONTROL VALVE SET


    1. Disconnect the 2 vacuum switching valve connectors.

    2. A00JXLJ

      Disconnect the 3 vacuum hoses, and then remove the 2 bolts and vacuum control valve set.

  17. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A00JZXEE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  18. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the pressure discharge valve connector.

    2. A00K0E5

      Remove the 2 bolts and common rail.

      Note

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