COMMON RAIL REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • B0068VK

    To prevent burns, do not remove the oil pan drain plug and oil filter sub-assembly while the engine is hot.


  • B0026TA

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • When replacing the common rail assembly, do not remove the foreign object mixing prevention caps of the common rail assembly until just before the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly are connected to the common rail assembly.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

PROCEDURE


  1. 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

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  3. REMOVE INTERCOOLER ASSEMBLY

    Click here

  4. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  5. REMOVE NO. 2 ENGINE UNDER COVER

  6. DRAIN ENGINE OIL

    Click here

  7. REMOVE MANIFOLD STAY

    Click here

  8. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

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

    Click here

  10. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  14. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the connector from the pressure discharge valve.

    2. Disconnect the connector from the fuel pressure sensor connector.

    3. B0028AQ

      Remove the 2 bolts, common rail assembly from the cylinder head sub-assembly.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor from the common rail assembly.

  15. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A01W9FW

      Remove the No. 2 intake manifold insulator from the cylinder head sub-assembly.