FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

Note:

  • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

  • When working on the fuel circuit, protect the generator assembly against dirt contamination.

    Cover the generator assembly with suitable materials.

    Failure to comply with this procedure may result in a generator assembly malfunction.

  • A316354E04

    After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

    SST

    PZ4TB-04941-79

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  3. REMOVE NO. 1 ENGINE COVER

    Click here

  4. REMOVE ENGINE COVER

    A314051

  5. REMOVE INJECTION PIPE SUB-ASSEMBLY

    A314052E02
    Note:

    Reset SST in a timely manner to prevent bending of pressure lines.

    1. Using SST, loosen the 4 union nuts at the common rail assembly end of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST

      PZ4TB-04959-10

    2. Using SST, loosen the 4 union nuts at the 4 injector assembly ends of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST

      PZ4TB-04959-10

    3. Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

  6. REMOVE CAMSHAFT POSITION SENSOR

    Click here

  7. DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

    1. A314053

      Disconnect the connector and detach the 2 clamps to disconnect the wire harness (Click here).

    2. A340051E02

      Pull up the 4 clips and disconnect the nozzle leakage pipe assembly from the 4 injector assemblies as shown in the illustration.

      Table 1. Text in Illustration

      *1

      Sealing Ring

      *2

      Leakage Line

      *3

      Clip

      *a

      Pull Up
      Note:

      If a sealing ring is damaged, the entire leakage line of a cylinder group must be replaced.

    3. Remove the 4 sealing rings from the nozzle leakage pipe assembly.

  8. REMOVE INJECTOR ASSEMBLY

    1. A314055

      Disconnect the 4 injector assembly connectors.

    2. A314056

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 4 centering rings.

    3. Remove the 4 clamping claws from the 4 injector assemblies.

    4. A314060E01

      Remove the 4 injector assemblies from the cylinder head cover sub-assembly.

      1. Pull out the injector assembly with light rotational movements.

        SST

        PZ4TB-04942-79

        Tip:

        • If an injector assembly is stuck tight, mount SST (rod) to the pressure line connection.

        • Move injector assembly with SST (rod) only by a few degrees.