Common Rail -- Removal |
- NOTICE:
- 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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- CAUTION:
- Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
- NOTICE:
- When disconnecting the cable, systems need to be initialized after the cable is reconnected (Toyota Fortuner RM000002HD2005X.html).
| 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. REMOVE INTERCOOLER ASSEMBLY |
| 6. REMOVE MANIFOLD STAY |
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Remove the 2 bolts and stay.
| 7. REMOVE OIL FILTER SUB-ASSEMBLY |
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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.
| 8. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY |
- 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 bolt and No. 2 injection pipe clamp.
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Remove the 2 nuts and No. 3 injection pipe clamp.
Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
| 9. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the 2 bolts and disconnect the 2 injection pipe clamps.
- NOTICE:
- If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
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| 10. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY |
Disconnect the 3 fuel hoses.
Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.
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| 11. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
Remove the engine oil level dipstick.
Remove the bolt and clamp.
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Remove the bolt and engine oil level dipstick guide.
Remove the O-ring engine oil level dipstick guide.
Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
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| 12. REMOVE COMMON RAIL ASSEMBLY |
Disconnect the 2 connectors.
Remove the 2 bolts, common rail and No. 2 intake manifold insulator.
- NOTICE:
- Do not remove the pressure discharge valve and fuel pressure sensor.
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