COMMON RAIL REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE ENGINE ROOM SIDE COVER


    1. A003B3G

      Remove the clip and engine room side cover.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • w/ Navigation System (for HDD):

      After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

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

  3. REMOVE NO. 1 ENGINE COVER


    1. A003DQW

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  4. DISCONNECT ENGINE WIRE

    A003BMP

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the grommet and nut, and disconnect the glow plug wire harness.

    4. Detach the 2 wire harness clamps.

    5. Remove the bolt and wire harness bracket.

    6. Remove the bolt and 3 nuts, and disconnect the engine wire.

  5. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A003DL2

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  6. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A003AJA

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  7. REMOVE COMMON RAIL ASSEMBLY


    1. A003B5S

      Using pliers, grip the claws of the clip and slide the clip to disconnect the fuel hose.

    2. Remove the 2 bolts and common rail.