FUEL INJECTOR (for Direct Injection) REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

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  3. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Disconnect the fuel pump connector.

    2. A01H1CZ

      Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the No. 3 fuel pipe sub-assembly from the fuel pump.

      Note

      Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump.

    3. A01GX74E01

      Remove the 2 bolts on the delivery pipe side and remove the No. 3 fuel pipe sub-assembly.

    4. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe sub-assembly.

  4. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tech Tips

    The removal procedures are the same as for the No. 3 fuel pipe sub-assembly.

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    A01H28P

  6. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

    A01GYRP

  7. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

    A01GXKU

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01GW61E06
      Text in Illustration
      *1 Union Nut Wrench

      Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub-assembly.

  9. REMOVE FUEL DELIVERY PIPE


    1. A01GWRB

      Disconnect the fuel relief valve connector and No. 3 fuel hose.

    2. A01GZUM

      Disconnect the 4 fuel injector connectors.

    3. A01GZ5W

      Remove the 5 bolts and fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  10. REMOVE NO. 2 FUEL DELIVERY PIPE


    1. A01H0D3

      Disconnect the fuel pressure sensor connector.

    2. A01H22N

      Disconnect the 4 fuel injector connectors.

    3. A01GXFD

      Remove the 5 bolts and No. 2 fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the No. 2 fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  11. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01GZJSE02

      Secure the fuel delivery pipe between aluminum plates in a vise and pull out the fuel injector assembly in a straight line.

      Note


      • Do not overtighten the vise.

      • Pull and remove the fuel injector assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe's O-ring.

      • For reinstallation, attach a tag or label to the fuel injector assembly shaft.

    2. Remove the nozzle holder clamp from the fuel injector assembly.

    3. Remove the O-ring, No. 1 backup ring, No. 2 backup ring, No. 3 backup ring and E-ring from the fuel injector assembly.

  12. REMOVE FUEL INJECTOR SEAL


    1. A01GY3F

      Using the tips of needle-nose pliers, pinch and pull one of the 2 fuel injector seals at several points to stretch it. Repeat this for the other fuel injector seal.

      Note


      • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.

      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.

    2. Remove the 2 fuel injector seals from the fuel injector assembly.

  13. REMOVE FUEL PIPE SUPPORT SUB-ASSEMBLY


    1. A01GZSCE01
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 No. 2 Fuel Delivery Pipe

      Remove the 4 bolts and 2 fuel pipe support sub-assemblies.

    2. Remove the 2 O-rings, 2 No. 1 backup rings, 2 No. 2 backup rings and 2 E-rings from the 2 fuel pipe support sub-assemblies.

  14. REMOVE FUEL DELIVERY PIPE PLUG


    1. A01GYR0E01
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 No. 2 Fuel Delivery Pipe

      Using a 6 mm hexagon socket wrench, remove the 2 fuel delivery pipe plugs and 2 gaskets from the fuel delivery pipe and No. 2 fuel delivery pipe.