Note
When replacing the common rail, also replace the injection pipe.
After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.
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.
REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)
Remove the 4 bolts and under cover.
REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)
Remove the 4 bolts and under cover.
DRAIN ENGINE OIL
LOOSEN FUEL TANK CAP ASSEMBLY
DRAIN FUEL
REMOVE INTERCOOLER ASSEMBLY
Remove the intercooler assembly Click here.
REMOVE MANIFOLD STAY
Disconnect the 3 vacuum hoses from the 2 VSV.
Remove the 2 bolts and stay.
REMOVE OIL FILTER SUB-ASSEMBLY
Using SST, remove the oil filter.
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 filter cover.
REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE
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.
Remove the 2 nuts and No. 3 injection pipe clamp.
Remove the 2 bolts and 2 No. 2 injection pipe clamps.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
REMOVE EGR COOLER ASSEMBLY
Remove the EGR cooler assembly Click here.
REMOVE NO. 4 INJECTION PIPE
Remove the bolt and disconnect the injection pipe clamp.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
Disconnect the 3 fuel hoses.
Remove the check valve, 3 bolts, leakage pipe and gasket.
REMOVE FUEL INLET PIPE SUB-ASSEMBLY
Remove the bolt and clamp.
Remove the bolt and oil level gauge guide.
Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
REMOVE COMMON RAIL ASSEMBLY
Disconnect the 2 connectors.
Remove the 2 bolts, common rail and insulator.
Note
Do not remove the pressure discharge valve and pressure sensor.