Removal and Installation of Common Rail

6) Holder attachment

Secure the flange (1-1) and stand the pins (31) straight up on the flange in 4 locations.

Use grease to attach the shim selected in 5) to the holder (6), and press fit the shim with it on the holder in alignment with the pin holes.

Mount the washers (7) on the holder, apply Loctite to the threaded sections, and tighten the bolts (8) to the specified torque.

Cautions: a.Check that the pins (31) have not fallen. b.The loosening stop spikes should be attached to the washers. Put the spikes on the holder seating surface side to mount them. c.Thoroughly clean the bolt threaded sections and apply Loctite after degreasing. d.Also thoroughly clean the internal areas of the screw holes of the flange, and thoroughly degrease them.

Be careful to attach the washers (7) in the correct direction. Attach them in the direction shown in the diagram above. *1 Holder side *2 Bolt seating surface side

7) Planetary gear attachment

Attach the thrust plates (9) to the planetary gears (12).

Next, attach the needle bearings (11) to the planetary gears.

Finally, after attaching the inner races (10), join the flange trunnion sections (4 locations) with the internal diameter sections of the inner races to attach the planetary gears.

Cautions: a.When attaching the thrust plates to the planetary gears, make sure the shear droop on the thrust plates created by the press is facing the 1-1 flange side. b.When finally attaching the planetary gears to the flange, attach them so that the internal teeth of the housing (4) engage with the planetary gear teeth. c.Be careful with the attachment directions of the planetary gears.

*1 Make the shear droop side face the planetary gear C (6) side. *2 Thrust plate (9) attachment direction

8) Thrust plate attachment

Mount the thrust plates (13) on the planetary gears (12) in such a way that the chamfers of the bolt hole sections are the neck bottom section of the bolts (14).

After mounting, mount the bolts that have had Loctite applied to the threaded sections and tighten them to the specified torque.

Cautions: a.Be careful with the mounting direction of the thrust plates. Mistakes could cause scratching on the bolt neck sections and this could result in damage. b.Thoroughly clean the bolt threaded sections and apply Loctite after degreasing. c.Also thoroughly clean the internal areas of the screw holes of the flange (1-1), and thoroughly degrease them.

9) Sun gear C attachment

After checking that the snap ring (16) is mounted on sun gear C (15), mount the sun gear C in the middle of the 4 planetary gears (12).

Caution: Mount the sun gear C so that the teeth engage with the teeth of the planetary gears.

*1 Mount so that the C2 chamfer side is the seating surface side for the hexagon socket head bolts.