FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

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 AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  7. DISCONNECT ENGINE WIRE

    A004OC3

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the grommet and nut and disconnect the glow plug wire harness.

    4. Detach the 2 wire harness clamps.

    5. Remove the bolt and wire harness bracket.

    6. Remove the bolt and 3 nuts and disconnect the engine wire.

  8. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A004PZG

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  9. REMOVE FUEL HOSE PROTECTOR

    Click here

  10. REMOVE FUEL TUBE SUB-ASSEMBLY

    Click here

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A004OSQ

      Disconnect the 3 fuel hoses.

    2. A004TP4

      Remove the check valve and gasket.

      Text in Illustration
      A004NAK Check Valve

    3. Remove the bolt and No. 2 nozzle leakage pipe.

  12. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A004MVJ

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  13. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A004QRF

      Disconnect the 4 injector connectors.

    2. A004ON3

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

  14. REMOVE INJECTOR ASSEMBLY


    1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

    2. Remove the O-ring from each injector.

      Note

      When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.