COMMON RAIL (w/o 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. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)

    Click here

  4. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  5. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  6. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  7. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ Intercooler)


    1. A01DYJJ

      Disconnect the vacuum switching valve connector.

    2. A01DZ46

      Disconnect the 3 vacuum transmitting hoses.

    3. A01DWYI

      Remove the 2 bolts and manifold stay with vacuum switching valve.

  8. REMOVE MANIFOLD STAY (w/o Intercooler)


    1. A01E344E01

      Remove the 2 bolts and manifold stay.

  9. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DYHFE01

      Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

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

  10. 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. w/ Intercooler:


      1. A01DWWA

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

      2. A01E1SS

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

      3. A01DXC6E01
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

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

    2. w/o Intercooler:


      1. A01DXPXE02
        Text in Illustration
        *1 No. 2 Injection Pipe Clamp
        *2 No. 3 Injection Pipe Clamp
        *a Injector Side
        *b Common Rail Side

        Remove the bolt and No. 2 injection pipe clamp.

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

      3. 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 NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)


    1. A01DVDTE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
      *1 No. 2 Intake Air Connector Bracket
      *2 Intake Air Connector

      Remove the 3 bolts and No. 2 intake air connector bracket.

  12. DISCONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)


    1. A01DZCR

      Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.

  13. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)


    1. w/ Intercooler:


      1. A01DZHP

        Disconnect the 2 connectors.

      2. A01E31V

        Disconnect the 6 vacuum hoses.

      3. Remove the bolt and No. 1 gas filter with gas filter bracket.

      4. A01DY7U

        Remove the 2 bolts and electric vacuum regulating valve.

    2. w/o Intercooler:


      1. A01DWIO

        Disconnect the connector.

      2. Disconnect the 2 vacuum hoses.

      3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.

        Note

        Do not remove the electric vacuum regulating valve from the bracket.

  14. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DZS6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  15. REMOVE INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DW3T

      Remove the 3 bolts, intake air connector and 2 gaskets.

  16. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01DX9H

      Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.

  17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note

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


    1. w/ Intercooler:


      1. A01E10I

        Remove the bolt and disconnect the injection pipe clamp.

      2. A01DVY2E07
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

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

    2. w/o Intercooler:


      1. A01E0ZRE01

        Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      2. A01E2XGE02
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

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

  18. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the 3 fuel hoses.

    2. A01DVNTE01
      Text in Illustration
      *1 Union Bolt

      w/ Intercooler:

      Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

    3. A01DYKDE01
      Text in Illustration
      *1 Union Bolt

      w/o Intercooler:

      Remove the union bolt, 2 bolts, No. 2 nozzle leakage pipe and gasket.

  19. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01DV94E01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler

      Remove the bolt and injection pipe clamp.

    2. Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  20. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E03WE11
      Text in Illustration
      *a Common Rail Side
      *b Fuel Supply Pump Side

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

  21. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the 2 connectors.

    2. A01DVT1

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

      Note

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