COMMON RAIL > REMOVAL

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NOTICE:
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 and seat belt pretensioner activation.



2. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD)

  1. Remove the 4 bolts and under cover.



3. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD)

  1. Remove the 4 bolts and under cover.



4. DRAIN ENGINE OIL


5. LOOSEN FUEL TANK CAP ASSEMBLY


6. DRAIN FUEL


7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    A110362

  1. Remove the 3 bolts, 2 nuts and cover.



8. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    A110365

  1. Disconnect the diesel turbo IAT sensor connector.

  1. Loosen the 2 hose clamps of the No. 1 air hose.



    A110366

  1. Loosen the 2 hose clamps of the No. 2 air hose.



    A110367

  1. Remove the 4 bolts and CAC.



    A112149

  1. Using a 22 mm deep socket wrench, remove the IAT sensor.

    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.



    A112150

  1. Remove the 4 bolts, intake air connector and gasket.



9. REMOVE MANIFOLD STAY


A099622E01

  1. Remove the 2 bolts and stay.



10. REMOVE OIL FILTER SUB-ASSEMBLY


B011502E01

  1. Using SST, remove the oil filter.

    SST
    09228-07501  

    HINT:
    Insert the drain hose in the oil filter. Put the drain oil container beneath the drain hose to collect the oil from the oil filter.



11. REMOVE INJECTION PIPE


A098967E02

NOTICE:
  1. After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
  2. After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

  1. Remove the 2 nuts and No. 3 injection pipe clamp.

  1. Remove the bolt and No. 2 injection pipe clamp.



  1. Using SST, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

    SST
    09023-12701  



      A098893E01

    1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.



      2. A098968E01

    2. Using SST, loosen the union nuts and remove the No. 4 injection pipe.

      SST
      09023-12701  



12. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


A098898E01

  1. Disconnect the 2 fuel hoses.

  1. Remove the check valve, 3 bolts, leakage pipe and gasket.



13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


G036615E01

  1. Remove the bolt and clamp.

  1. Remove the 2 bolts and oil level gauge guide.



    A098969E01

  1. Using SST, loosen the union nuts and remove the fuel inlet pipe.

    SST
    09023-12701  



14. REMOVE COMMON RAIL ASSEMBLY


A098899E01

  1. Disconnect the fuel pressure sensor connector.

  1. Remove the 2 bolts and common rail.

    NOTICE:
    Do not remove the pressure limiter and pressure sensor.