COMMON RAIL (w/ 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 and seat belt pretensioner activation.

  2. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 4 bolts and under cover.

  3. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 4 bolts and under cover.

  4. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug, and drain the engine oil from the oil pan.

      Note

      Collect the oil in an oil disposal container.

  5. REMOVE FUEL TANK CAP ASSEMBLY

  6. REMOVE INTERCOOLER ASSEMBLY


    1. Remove the intercooler assembly Click here.

  7. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    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.

  8. REMOVE OIL FILTER SUB-ASSEMBLY

    A01DXRME01

    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Insert the drain hose in the oil cooler cover. Put the disposal container beneath the drain hose to collect the oil from the oil cooler cover.

  9. 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. A01DZU7E01

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

    2. A01DYA8E01

      Remove the 2 bolts and 2 No. 2 injection pipe clamps.

    3. A01DWONE05

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  10. REMOVE EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE


    1. Remove the EGR cooler with electric EGR control valve and No. 2 EGR valve Click here.

  11. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

      Note

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

    2. A01DVY2E05

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

  12. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01DVSCE02

      Disconnect the 3 fuel hoses.

    2. Remove the check valve, 3 bolts, leakage pipe and gasket.

  13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E02G

      Remove the bolt and clamp.

    2. A01E1CP

      Remove the bolt and oil level gauge guide.

    3. A01E0LTE03

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

  14. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the 2 connectors.

    2. A01DYVV

      Remove the 2 bolts, common rail and No. 2 intake manifold insulator.

      Note

      Do not remove the pressure discharge valve and pressure sensor.