Common rail (fuel rail) removal (4JJ3 with DPD)

1. Component views

Common rail (fuel rail)

Part name

  1. Cylinder block cover
  2. Common rail (fuel rail)
  3. Bolt
  4. Cylinder block

Tightening torque

3: 51 N・m { 5.2 kgf・m / 38 lb・ft }

2. Intake throttle valve removal

Refer to "1.Engine 1B.Mechanical(4JJ3 with DPD) Intake throttle valve removal".

3. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge guide tube.

2) Remove the oil level gauge guide tube from the crankcase.

4. Air duct bracket removal

1) Remove the air duct bracket from the cylinder head cover.

5. Battery removal

1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

Legend

  1. Battery cable
  2. Battery bracket
  3. Battery ground cable

6. A/C compressor drive belt removal

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley
  • Idle pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. Idle pulley
  4. A/C compressor drive belt
  5. Idle pulley

7. A/C compressor disconnect

1) Disconnect the A/C compressor from the A/C compressor bracket.

Legend

  1. A/C compressor bracket
  2. A/C compressor

8. Leak-off pipe removal

1) Remove the harness bracket from the inlet manifold.

Legend

  1. Harness bracket

2) Disconnect the 3 vacuum hoses from the vacuum pipe.

3) Disconnect the 2 leak-off hoses from the leak-off pipe.

4) Remove the leak-off pipe from the inlet manifold.

Legend

  1. Leak-off hose (Injector side)
  2. Leak-off pipe
  3. Vacuum pipe
  4. Vacuum hose (EGR cooler bypass control solenoid valve side)
  5. Leak-off hose (Supply pump side)
  6. Vacuum hose (Vacuum pump side)

9. EGR cooler bypass control solenoid valve removal

1) Disconnect the connector from the EGR cooler bypass control solenoid valve.

2) Disconnect the vacuum hose from the EGR cooler bypass control solenoid valve.

3) Remove the EGR cooler bypass control solenoid valve and bracket as a set from the inlet manifold.

Legend

  1. EGR cooler bypass control solenoid valve

10. Fuel leak-off pipe removal

1) Remove the fuel leak-off pipe from the fuel supply pump and common rail (fuel rail).

Caution

  • Cover the exposed section to prevent the intrusion of foreign material.

Legend

  1. Leak-off hose
  2. Fuel leak-off pipe

11. Fuel feed pipe removal

1) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

Caution

  • Do not reuse the fuel feed pipe.
  • Cover the exposed section to prevent the intrusion of foreign material.

Legend

  1. Fuel supply pump
  2. Fuel feed pipe
  3. Common rail (fuel rail)

12. Injection pipe removal

1) Remove the clip from the injection pipe.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution

  • Do not reuse the injection pipe.

Legend

  1. Injection pipe
  2. Clip

13. Common rail (fuel rail) removal

1) Disconnect the connector from the FRP sensor.

Note

  • Disconnect it between the engine harness and the sub-harness.

Legend

  1. Common rail (fuel rail)
  2. FRP sensor connector

2) Disconnect the fuel leak-off hose from the common rail (fuel rail).

3) Remove the common rail (fuel rail) from the cylinder block.

Caution

  • Do not hold the FRP sensor or pressure-reducing valve.
  • Do not damage the FRP sensor or pressure-reducing valve.

Legend

  1. FRP sensor
  2. Common rail (fuel rail)
  3. Pressure-reducing valve
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