COMMON RAIL REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the common rail assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Battery terminal is disconnected/reconnected Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes) Stop and start system

Click here

Memorize steering angle neutral point Pre-collision system

Click here

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Fuel inlet pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck or dropped.

  • Hold the common rail assembly itself during removal and installation. Do not hold the pressure discharge valve or fuel pressure sensor, etc.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  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 EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Cooler)

    Click here

  4. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)

    Click here

  5. REMOVE EGR VALVE ADAPTER (w/o EGR Cooler)

    Click here

  6. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  7. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  9. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 4 FUEL HOSE


    1. B0024S0

      Slide the clamp and disconnect the No. 4 fuel hose from the common rail assembly.

  11. REMOVE COMMON RAIL ASSEMBLY


    1. B0024U5

      Detach the wire harness clamp.

    2. Disconnect the fuel pressure sensor connector from the common rail assembly.

    3. B0024U7

      Remove the 2 nuts and common rail assembly.

      Note

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