COMMON RAIL(w/ Glow Plug Controller) REMOVAL

CAUTION / NOTICE / HINT

Note:

  • When replacing the injector assemblies (including exchanging the injector assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.

  • When replacing the injector assemblies, supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.

PROCEDURE

  1. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  3. REMOVE NO. 1 GLOW PLUG CONNECTOR

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  4. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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  5. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    Note:

    Perform installation and removal procedures by hand only. Do not use any tools.

    1. Slide the clip and disconnect the nozzle leakage pipe assembly from the No. 2 nozzle leakage pipe.

      A353576C01

      *a

      Lock Bush

      -

      -
      V100137

      Pull up

      -

      -

    2. Disengage the clamp to disconnect the nozzle leakage pipe assembly from the hose clamp.

    3. Pull up the 4 lock bushes of the nozzle leakage pipe assembly as shown in the illustration, and remove it from each injector assembly.

  6. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

    1. A353578

      Using a 17 mm union nut wrench, loosen the 2 union nuts, and remove the No. 1 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note:

      To prevent contamination by foreign matter, after removing the No. 1 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  7. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    1. A353580

      Using a 17 mm union nut wrench, loosen the 2 union nuts, and remove the No. 2 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note:

      To prevent contamination by foreign matter, after removing the No. 2 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  8. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    1. A349603

      Disconnect the vacuum hose from the No. 2 EGR valve assembly.

    2. A349604

      Remove the bolt and separate the vacuum transmitting pipe sub-assembly from the EGR cooler bracket.

    3. A353582

      Using a 17 mm union nut wrench, loosen the 2 union nuts, and remove the No. 3 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note:

      To prevent contamination by foreign matter, after removing the No. 3 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    1. A349606

      Remove the bolt and No. 3 engine cover bracket from the EGR cooler bracket.

    2. A353584

      Remove the bolt and No. 2 injection pipe clamp from the fuel inlet pipe sub-assembly and No. 4 injection pipe sub-assembly.

    3. A353585

      Using a 17 mm union nut wrench, loosen the 2 union nuts, and remove the fuel inlet pipe sub-assembly from the injector assembly and common rail assembly.

      Note:

      To prevent contamination by foreign matter, after removing the fuel inlet pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  10. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    1. A353587

      Using a 17 mm union nut wrench, loosen the 2 union nuts, and remove the No. 4 injection pipe sub-assembly from the injector assembly and common rail assembly.

      Note:

      To prevent contamination by foreign matter, after removing the No. 4 injection pipe sub-assembly, protect the connecting portions of the injector assembly and common rail assembly with plastic bags.

  11. REMOVE COMMON RAIL ASSEMBLY

    1. A353589

      Disconnect the rail pressure sensor connector.

    2. A353590

      Disconnect the pressure control valve connector.

    3. A353591

      Slide the clip and disconnect the No. 2 fuel hose from the common rail assembly.

    4. A349613

      Remove the 2 bolts.

    5. A353592

      Disengage the clamp, and while disconnecting the No. 4 water by-pass hose, remove the common rail assembly from the cylinder head sub-assembly.

    6. A349615

      Disengage the clamp to remove the hose clamp from the common rail assembly.