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COMMON RAIL REMOVAL

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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.

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  1. Click here

    REMOVE BATTERY SERVICE HOLE COVER


    1. A01ITOM

      Remove the clip and battery service hole cover.

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    PRECAUTION

    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).

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    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

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    REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      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.

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    DISCONNECT ENGINE WIRE


    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the screw 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.

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    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. A01IO2G

      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.

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    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. A01ITN1

      Remove the nut and 2 clamps.

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

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    REMOVE COMMON RAIL ASSEMBLY


    1. A01IUFT

      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.