COMMON RAIL (w/ EGR Cooler) REMOVAL

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.


  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 (for 4WD)


    1. Remove the 4 bolts and under cover.

  3. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)


    1. Remove the 4 bolts and under cover.

  4. DRAIN ENGINE OIL

  5. LOOSEN FUEL TANK CAP ASSEMBLY

  6. DRAIN FUEL

  7. REMOVE INTERCOOLER ASSEMBLY


    1. Remove the intercooler assembly Click here.

  8. REMOVE MANIFOLD STAY


    1. Disconnect the 3 vacuum hoses from the 2 VSV.

    2. A01E1Y6

      Remove the 2 bolts and stay.

  9. 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 filter cover.

  10. 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.


    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. A01DWONE02

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

  11. REMOVE EGR COOLER ASSEMBLY


    1. Remove the EGR cooler assembly Click here.

  12. REMOVE NO. 4 INJECTION PIPE


    1. A01E10I

      Remove the bolt and disconnect the injection pipe clamp.

    2. A01DVY2E02

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

  13. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DVSC

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

  14. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E02G

      Remove the bolt and clamp.

    2. A01E1CP

      Remove the bolt and oil level gauge guide.

    3. A01E0LTE02

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

  15. REMOVE COMMON RAIL ASSEMBLY


    1. A01DX72

      Disconnect the 2 connectors.

    2. Remove the 2 bolts, common rail and insulator.

      Note

      Do not remove the pressure discharge valve and pressure sensor.