COMMON RAIL (w/o DPF) 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

  2. REMOVE EGR COOLER ASSEMBLY

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  3. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. B007QNX

      Disconnect the 4 injector connectors.

    2. Remove the 4 bolts and detach the 3 clamps.

    3. B007UUH

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

    4. B007TC6

      Using a 17 mm union nut wrench, loosen the union nuts and remove the 4 injection pipes.

  4. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. B007SVQE01

      Remove the bolt and No. 2 injection pipe clamp.

    2. Remove the bolt and detach the No. 1 injection pipe clamp.

      Note

      If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.

    3. B007RXX

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

  5. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the pressure discharge valve connector and fuel pressure sensor connector.

    2. B007QVL

      Disconnect the fuel hose.

    3. B007VN8

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.