FUEL INJECTOR REMOVAL

Note


  • When removing the injection pipes, clean them up with a brush and compressed air.

  • When installing, clean up the seal surface of the injector, injection pipe, fuel inlet pipe, supply pump and common rail with clean light oil.

  • When replacing the injectors and/or common rail, it is necessary to replace injection pipes, as well.

  • When replacing the supply pump and/or common rail, it is necessary to replace the fuel inlet pipe, as well.


  1. DISCONNECT BATTERY NEGATIVE TERMINAL

  2. REMOVE FRONT SEAT ASSEMBLY RH (W/O TILT CAB CAB TYPE)

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  3. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)

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  4. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Remove the clip and nut, and then Disconnect the select cable from the transmission.

  5. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Remove the clip and nut, and then Disconnect the shift cable from the transmission.

  6. DISCONNECT TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)

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  7. DISCONNECT PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

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  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Remove the front door scuff.

    2. Remove the floor mat.

    3. Remove the 7 bolts and engine service hole sub-cover.

  9. REMOVE VSV ASSEMBLY

  10. DISCONNECT ENGINE WIRE

  11. REMOVE INJECTION PIPE SET


    1. Remove the 2 nuts and injection pipe clamp No. 3.

    2. Remove the bolt and injection pipe clamp No. 2.

    3. Remove the bolt and injection pipe clamp No. 1.

    4. A01KHC6

      Using a 17 mm union nut wrench, loosen the injection pipe unions of common rail side.

    5. Using a 17 mm union nut wrench, loosen the injection pipe unions of injector side.

      Note


      • After removing the fuel pipe, affix the gum tape to the common rail for preventing dust.

      • After removing the fuel pipe, put a vinyl bag and rubber band to prevent mixing foreign objects over the injectors inlet.

  12. REMOVE NOZZLE HOLDER SEAL

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

  14. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Remove the union bolt, 4 hollow screws, nozzle leakage pipe assembly and 5 gaskets from the cylinder head and injector.

      Note


      • When removing the return pipe, place a shop rag or the likes under the pipe.

      • Pay attention not to deform or scratch the union seal surface.

  15. REMOVE NOZZLE HOLDER CLAMP


    1. Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  16. REMOVE INJECTOR ASSEMBLY


    1. Disconnect the 4 injectors from the cylinder head.

      Tech Tips

      Arrange the injectors, clamps, washers and bolts in the correct order.

    2. A01KF3PE01
      Text in Illustration
      *1 Back-Up Ring
      *2 O-Ring

      Remove the O-ring and back-up ring from each injector.

    3. Remove the 4 nozzle seats from the cylinder head.