WARNING:
Place “NO OPEN FLAMES” signs near the working area.
CAUTION:
• Be careful not to spill fuel.
• Catch the fuel from hoses and pipes using a container or cloth.
• Always cover the ends of disconnected hoses and pipes with a plastic bag so that foreign matter does not get into the fuel system.
• Make sure that water, oil and other foreign matter does not get into the common rail pressure sensor connector.
• If the fuel delivery pipe nuts become loose, always replace the fuel delivery pipes with new parts.
1. Disconnect the ground cable from battery.
2. Remove the engine from vehicle. 
3. Remove the intake manifold.
4. Disconnect the harness connectors of the camshaft position sensor, glow plugs and fuel injectors (#1 and #3).
5. Disconnect the harness connector from the oil pressure switch.
6. Disconnect the harness connectors of the engine coolant temperature sensor, glow plug and fuel injectors (#2 and #4), and disconnect the air breather hose from the rocker cover (LH).
7. Disconnect the harness connectors of the suction control valve and fuel temperature sensor, and remove the harness clip from the pipe.
8. Disconnect the harness connector from the common rail pressure sensor.
9. Remove the service hole of the crankshaft position sensor, and disconnect the harness connector.
10. Remove the engine harness.
11. Remove the rocker cover.
12. Remove the fuel return pipes.
13. Remove the fuel pipe.
• LHD model
• RHD model
14. Remove all fuel delivery pipe nuts from the common rail assembly and fuel pump.
15. Remove the fuel delivery pipes between the fuel pump and common rail assembly.
16. Remove the fuel delivery pipe nuts from the fuel injectors.
17. Remove the fuel pipe holder (A) and fuel pipe holder stay (B).
18. Remove the cap bolts.
19. Remove the fuel delivery pipes.
20. Remove the clips (A), and the seals (B) from the cap.
21. Loosen the bolts on the common rail assembly.
22. Remove the fuel return pipes.
23. Remove the fuel injector.
1. Disconnect the ground cable from battery.
2. Remove the engine from vehicle.
3. Remove the intake manifold.
4. Disconnect the harness connectors of the camshaft position sensor, glow plugs and fuel injectors (#1 and #3).
5. Disconnect the harness connectors of the engine coolant temperature sensor, oil pressure switch and fuel injectors (#2 and #4), and disconnect the air breather hose from the rocker cover (LH).
6. Disconnect the harness connectors of the suction control valve and fuel temperature sensor, and remove the harness clip from the pipe.
7. Disconnect the harness connector from the common rail pressure sensor.
8. Remove the service hole of the crankshaft position sensor, and disconnect the harness connector.
9. Remove the engine harness.
10. Remove the fuel return hoses, bolts and nuts as shown in the following figure, and remove the fuel return pipes.
• LHD model
• RHD model
11. Remove the fuel pipe protector from the rear of the cylinder head (LH).
12. Remove the fuel return pipes from the cylinder head.
|
(A) |
LH side |
(B) |
RH side |
13. Remove the rocker cover.
14. Remove the fuel return pipes.
