COMMON RAIL (w/o EGR Cooler) 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

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

    Note

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

  2. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)


    1. Remove the 4 bolts and No. 1 engine under cover.

  3. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)


    1. Remove the 2 bolts and No. 2 engine under cover.

  4. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    A01E0K7

    1. Disconnect the manifold absolute pressure sensor connector.

    2. Disconnect the vacuum hose from the gas filter.

    3. Loosen the 2 clamps.

    4. Remove the bolt and disconnect the pipe together with the 2 air hoses.

  5. REMOVE MANIFOLD STAY


    1. w/ EGR Cooler:


      1. Disconnect the 2 VSV connector and 3 vacuum hoses.

      2. A01E1Y6

        Remove the 2 bolts and manifold stay.

    2. w/o EGR Cooler:


      1. A01E344E01

        Remove the 2 bolts and manifold stay.

  6. REMOVE OIL FILTER SUB-ASSEMBLY

    A01DVQRE01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Insert the drain hose in the oil filter. Put the drain oil container beneath the drain hose to collect the oil from the oil filter.

  7. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


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

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


    1. A01E30RE05

      Remove the bolt and No. 2 injection pipe clamp.

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

    3. 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 NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E0ZRE01

      Remove the 2 bolts.

      Note

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

    2. A01E2XGE01

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

  9. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DWIZE03

      Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Remove the engine oil level dipstick.

    2. A01DW6AE01

      Remove the bolt and clamp.

    3. Remove the bolt and engine oil level dipstick guide.

    4. Remove the O-ring engine oil level dipstick guide.

    5. A01E03WE03

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

  11. REMOVE COMMON RAIL ASSEMBLY


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

    2. A01E2QU

      Remove the 2 bolts and common rail.

      Note

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