Common Rail Removal


  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE EGR COOLER ASSEMBLY

  4. REMOVE WIRING HARNESS CLAMP BRACKET

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

  6. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

  7. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

  8. REMOVE NO. 4 FUEL HOSE

  9. REMOVE COMMON RAIL ASSEMBLY

Common Rail -- Removal


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

    Replaced Parts (A)
    		Pipes Requiring New Replacement
    1. Injector assembly (including shuffling the injector assemblies between the cylinders)
    2. Common rail assembly
    3. Cylinder head sub-assembly
    1. No. 1 injection pipe sub-assembly
    2. No. 2 injection pipe sub-assembly
    1. Supply pump assembly
    2. Common rail assembly
    3. Cylinder block sub-assembly
    4. Cylinder head sub-assembly
    5. Cylinder head gasket
    6. Timing chain case assembly
    1. No. 1 injection pipe sub-assembly
    2. No. 2 injection pipe sub-assembly
    3. Fuel inlet pipe sub-assembly
  2. 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.
  3. The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.
  4. Make sure foreign matter does not enter the fuel path.


1. PRECAUTION
NOTICE:
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. (LandCruiser RM000003YMD00TX.html)


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. (LandCruiser RM000003YMF011X.html)


3. REMOVE EGR COOLER ASSEMBLY
(LandCruiser RM000005UJV000X.html)


4. REMOVE WIRING HARNESS CLAMP BRACKET


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Disconnect the pressure discharge valve connector from the common rail assembly.

  1. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.



5. REMOVE REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY
NOTICE:
After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Fuel.Fuel System.Common Rail Removal

  1. Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

    SST
    09245-11010


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

    NOTICE:
    When removing the No. 1 injection pipe subassembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.


6. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Fuel.Fuel System.Common Rail Removal
Text in Illustration
*a
Common Rail Assembly Side
*b
Fuel Supply Pump Assembly Side

  1. Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Fuel.Fuel System.Common Rail Removal

  1. Text in Illustration
    *a
    		SST
    Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.
    SST
    09245-11010
    NOTICE:
    If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1 or No. 2 injection clamp with a new one.

  1. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump assembly side.



7. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Text in Illustration
Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Union Bolt
Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Bolt

  1. Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe (LandCruiser RM0000028RU05SX.html).

  1. Remove the bolt from the intake manifold.

  1. Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.



8. REMOVE NO. 4 FUEL HOSE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

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



9. REMOVE COMMON RAIL ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Detach the wire harness clamp.

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

  1. Remove the 2 nuts and common rail assembly.

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