COMMON RAIL REMOVAL


  1. REMOVE BATTERY SERVICE HOLE COVER (w/ Sub-Battery)

  2. DISCONNECT BATTERY NEGATIVE CABLE

  3. REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      B007TROE01
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Reservoir Cap Sub-assembly
      *3 Radiator Reservoir Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block drain cock plug (on the engine oil cooler cover), and drain the engine coolant.

    4. Tighten the radiator drain cock plug.

    5. Tighten the cylinder block drain cock plug (on the engine oil cooler cover).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. B007T2L

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  6. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. B007OW8

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  7. REMOVE FRONT DOOR SCUFF PLATE RH

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the engine service hole sub cover assembly.

  9. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. B007TSM

      Remove the 2 bolts. Separate the vane pump oil reservoir assembly.

  10. DISCONNECT OIL RETURN HOSE (w/ Inter Cooler)


    1. B007T4F

      Loosen the clip.

    2. Disconnect the oil return hose from the intake manifold.

  11. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. B007QY1

      Disconnect the fuel pressure sensor connector.

    2. B007S6J

      Remove the 2 bolts, 2 nuts, and the EGR pipe sub-assembly.

    3. Remove the 2 gaskets.

  12. REMOVE AIR HOSE NO.4


    1. B007S1N

      Loosen the 2 clamps.

    2. Remove the air hose No.4.

  13. REMOVE ENGINE THROTTLE BODY ASSEMBLY


    1. B007RAM

      Disconnect the 2 throttle body connectors.

    2. B007PX5

      Remove the 2 bolts, 2 nuts, and the diesel throttle body assembly.

    3. Remove the gasket from intake air connector.

  14. REMOVE ENGINE SERVICE HOLE COVER NO.2


    1. B007PAF

      Roll up the carpet.

    2. Remove the 3 bolts and the engine service hole cover No.2.

  15. REMOVE INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. B007OKQ

      Remove the bolt, and separate the manifold stay.

    2. Disconnect the vacuum hose from intake air connector.

    3. B007OQ4E01

      Remove the bolt, 2 nuts and the intake air connector assembly.

    4. Remove the 2 gaskets and intake air connector No.2 from the intake air connector.

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Remove the vacuum regulating valve.


      1. B007SOX

        Remove the 2 vacuum hoses and the vacuum regulating valve connector.

      2. Remove the 2 bolts and the vacuum regulating valve.

    2. Remove the EGR valve assembly with the sensor.


      1. B007VH5

        Remove the bolt, and separate the manifold stay.

      2. Disconnect the vacuum hose from the intake air connector.

      3. B007Q7Z

        Disconnect the intake air temperature sensor connector.

      4. Disconnect the EGR valve position sensor connector.

      5. B007UFUE01

        Remove the bolt, 2 nuts and the intake air connector assembly.

      6. Remove the 2 gaskets and EGR valve assembly from the intake air connector.

  17. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the oil level gauge.

    2. Remove the bolt and oil level gauge guide.

  18. REMOVE INJECTION PIPE

    SST
    09023-12701

    1. Remove the injection pipe.


      1. B007SS6

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

      2. B007QK6

        Using SST, remove the 4 injection pipes.

        SST
        09023-12701

  19. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. Using SST, remove the fuel inlet pipe sub-assembly.

      SST
      09023-12701

  20. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. B007UT3

      Disconnect 3 fuel hoses from nozzle leakage pipe assembly No.2.

    2. B007PKJ

      Remove the union bolt from nozzle leakage pipe No.2.

    3. B007SQW

      Remove the 2 bolts and nozzle leakage pipe No.2.

    4. Remove the gasket from nozzle leakage pipe No.2.

  21. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the fuel pressure sensor connector from the common rail assembly.

    2. Disconnect the fuel hose from the fuel pressure limiter.

    3. B007RO1E01

      Remove the 2 bolts and common rail assembly.