COMMON RAIL REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

    • When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A316354N01

      After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

      SST

      PZ4TB-04941-79

  2. REMOVE INTAKE MANIFOLD

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  3. REMOVE INJECTION PIPE SUB-ASSEMBLY

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  4. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    1. A316271C01

      *1

      Rubber Grommet

      *2

      Rubber Mount

      Using SST, loosen the union nut at the common rail assembly end of the fuel inlet pipe sub-assembly.

      SST

      PZ4TB-04959-10

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

    2. Using SST, loosen the union nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

      SST

      PZ4TB-04959-10

      Note:

      Reset SST in a timely manner to prevent bending of pressure lines.

    3. Remove the fuel inlet pipe sub-assembly from the rubber grommet and rubber mount.

  5. REMOVE COMMON RAIL ASSEMBLY

    1. A316282

      Disconnect the fuel pressure sensor connector.

    2. A340054

      Disconnect the pressure discharge valve assembly connector.

    3. A340055C01

      *a

      Push

      Push at the location shown in the illustration and disconnect the fuel return tube.

    4. A316281

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 2 common rail assembly brackets.

    5. Remove the common rail assembly from the cylinder head cover sub-assembly.

  6. REMOVE FUEL PRESSURE SENSOR

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  7. REMOVE PRESSURE DISCHARGE VALVE ASSEMBLY

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