FUEL INJECTOR (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. CHECK FOR INJECTOR COMPENSATION CODE

    Tech Tips

    If the injector compensation code is not correctly registered, it may cause malfunctions.


    1. Read the injector compensation code Click here.

    2. Check that the compensation code of the installed injector is the same as the code registered in the ECM. If the code is not the same, register the injector compensation code on the injector Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  4. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KHEI

      Disconnect the 3 fuel hoses.

    2. Remove the fuel check valve and gasket from the No. 3 nozzle leakage pipe.

      Text in Illustration
      A01KGZT Fuel Check Valve

    3. Remove the bolt and No. 2 injection pipe clamp from the No. 3 nozzle leakage pipe and No. 3 fuel pipe.

    4. Remove the bolt and No. 3 nozzle leakage pipe.

  5. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    A01KIH2

    1. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

  6. REMOVE NO. 3 FUEL PIPE

    A01KHV0
    Text in Illustration
    A01KGZT Union Bolt A01KF96 Fuel Check Valve
    A01KFFI Bolt - -

    1. Remove the 2 union bolts and gasket from the No. 3 fuel pipe.

    2. Remove the fuel check valve and gasket from the No. 3 fuel pipe.

    3. Remove the 3 bolts and No. 3 fuel pipe.

  7. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01KIIV

      Remove the union bolt and gasket from the No. 2 nozzle leakage pipe assembly.

      Text in Illustration
      A01KGZT Union Bolt

    2. Remove the 3 bolts and No. 2 nozzle leakage pipe assembly.

  8. SEPARATE ENGINE WIRE


    1. A01KEV0

      Disengage the wire harness clamp, separate the glow plug connector.

    2. Disconnect the 10 connectors.

      A01KG4T

    3. Remove the 4 bolts.

    4. Disengage the 4 wire harness clamps, separate the engine wire.

  9. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01KFWX

      Remove the 3 bolts and 3 No. 2 injection pipe clamps.

    2. A01KF34

      Using a union nut wrench 17 mm, remove the No. 1 to No. 4 injection pipe sub-assembly.

  10. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


    1. A01KI8G

      Remove the No. 1 intake manifold insulator from the intake manifold.

  11. REMOVE COMMON RAIL ASSEMBLY


    1. A01KI78

      Remove the 2 bolts and common rail assembly.

  12. REMOVE NO. 1 CYLINDER HEAD COVER SILENCER


    1. A01KGHU

      Remove the No. 1 cylinder head cover silencer from the cylinder head cover sub-assembly.

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01KHM1J01

      Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.

    2. Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    3. A01KG8L

      Remove the 10 bolts, 2 nuts, cylinder head cover sub-assembly and the cylinder head cover gasket.

      Text in Illustration
      A01KFFI Bolt
      A01KGZT Nut
    4. A01KGGW

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

  14. REMOVE FUEL INJECTOR


    1. A01KHBVJ02

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01KEL8J01

      Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

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