GSIC - Global Service Information Center

# 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

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

8. REMOVE CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

1. Disconnect the diesel turbo IAT sensor connector.

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

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

1. Remove the 4 bolts and CAC.

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.

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

9. REMOVE MANIFOLD STAY

1. Remove the 2 bolts and stay.

10. REMOVE OIL FILTER SUB-ASSEMBLY

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

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

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

   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

1. Disconnect the 2 fuel hoses.

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

13. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

1. Remove the bolt and clamp.

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

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

   SST
     09023-12701

14. REMOVE COMMON RAIL ASSEMBLY

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.