Common Rail -- Removal |
- NOTICE:
- After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.
- When replacing the common rail, also replace the injection pipe and fuel inlet pipe.
| 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- CAUTION:
- Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
| 2. REMOVE NO. 1 ENGINE UNDER COVER |
Remove the 4 bolts and under cover.
| 3. REMOVE NO. 2 ENGINE UNDER COVER |
Remove the 2 bolts and under cover.
| 4. DRAIN ENGINE OIL |
Remove the oil filler cap.
Remove the oil drain plug, and drain the engine oil from the oil pan.
- NOTICE:
- Collect the oil in an oil disposal container.
| 5. LOOSEN FUEL TANK CAP ASSEMBLY |
| 6. DRAIN FUEL |
| 7. REMOVE NO. 1 ENGINE COVER |
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Remove the 3 bolts, 2 nuts and engine cover.
| 8. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR |
Disconnect the diesel turbo IAT sensor connector.
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Loosen the 2 hose clamps of the No. 1 air hose.
Loosen the 2 hose clamps of the No. 2 air hose.
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Remove the 4 bolts and CAC.
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Using a 22 mm deep socket wrench, remove the IAT sensor and gasket.
- HINT:
- Replace the IAT sensor if it is deformed, cracked or malfunctioning. It is not necessary to replace the IAT sensor each time the CAC is replaced.
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Remove the 4 bolts, intake air connector and gasket.
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| 9. REMOVE MANIFOLD STAY |
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Remove the 2 bolts and stay.
| 10. REMOVE OIL FILTER |
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Using SST, remove the oil filter.
- SST
- 09228-07501
- HINT:
- Insert the drain hose in the oil filter. Put the disposal container beneath the drain hose to collect the oil from the oil filter.
| 11. REMOVE INJECTION PIPE |
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- NOTICE:
- 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.
Remove the 2 nuts and No. 3 injection pipe clamp.
Remove the bolt and No. 2 injection pipe clamp.
Using union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
Using union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
| 12. REMOVE NO. 2 NOZZLE LEAKAGE PIPE |
Disconnect the 2 fuel hoses.
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Remove the check valve, 3 bolts, leakage pipe and gasket.
| 13. REMOVE FUEL INLET PIPE |
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Remove the bolt and clamp.
Remove the bolt and oil dipstick guide.
Using union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
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| 14. REMOVE COMMON RAIL |
Disconnect the fuel pressure sensor connector.
Remove the 2 bolts and common rail.
- NOTICE:
- Do not remove the pressure limiter and pressure sensor.
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