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 |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Toyota Fortuner RM000004W63000X.html).
| 2. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
| 3. REMOVE NO. 1 ENGINE UNDER COVER |
| 4. REMOVE NO. 2 ENGINE UNDER COVER |
| 5. DRAIN ENGINE OIL |
Remove the oil filler cap.
Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
Wipe the oil pan and drain plug.
Install a new gasket and the oil pan drain plug.
- Torque:
- 34 N*m{347 kgf*cm, 25 ft.*lbf}
| 6. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE |
Disconnect the vacuum switching valve connector.
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Disconnect the 3 vacuum transmitting hoses.
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Remove the 2 bolts and manifold stay with vacuum switching valve.
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| 7. REMOVE OIL FILTER SUB-ASSEMBLY |
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.
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| 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 2 nuts and No. 3 injection pipe clamp.
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Remove the 2 bolts and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a Injector Side *b Common Rail Side
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| 9. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET |
Remove the 3 bolts and No. 2 intake air connector bracket.
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| 10. DISCONNECT NO. 3 WATER BY-PASS PIPE |
Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.
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| 11. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (for EGR) |
Disconnect the 2 connectors.
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Disconnect the 6 vacuum hoses.
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Remove the bolt and No. 1 gas filter with gas filter bracket.
Remove the 2 bolts and electric vacuum regulating valve.
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| 12. REMOVE NO. 2 INTAKE AIR CONNECTOR |
Remove the 3 nuts, No. 2 intake air connector and gasket.
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| 13. REMOVE INTAKE AIR CONNECTOR |
Remove the 3 bolts, intake air connector and 2 gaskets.
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| 14. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY |
Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.
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| 15. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt and disconnect the injection pipe clamp.
- 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.
Text in Illustration *a Injector Side *b Common Rail Side
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| 16. 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.
Text in Illustration *1 Union Bolt
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| 17. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE |
Remove the engine oil level dipstick.
Remove the bolt and injection pipe clamp.
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Remove the bolt and engine oil level dipstick guide.
Remove the O-ring from the engine oil level dipstick guide.
| 18. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
Text in Illustration *a Common Rail Side *b Fuel Supply Pump Side
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| 19. 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 or pressure sensor.
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