FUEL INJECTOR (w/o 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, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. 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 as specified, register the injector compensation code of the injector Click here.

  3. REMOVE EGR COOLER ASSEMBLY

    Click here

  4. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A003BH2E01

      Remove the bolt and No. 2 injection pipe clamp.

    2. Remove the bolt and detach the No. 1 injection pipe clamp.

      Note

      If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.

    3. A003CA9

      Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

  5. REMOVE VACUUM SWITCHING VALVE BRACKET


    1. A003DYV

      Disconnect the vacuum switching valve connector and 2 vacuum hoses.

    2. Remove the bolt and vacuum switching valve bracket.

  6. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A003GFS

      Disconnect the 3 fuel hoses.

    2. A003FH3E01

      Remove the union bolt, 3 bolts, No. 2 nozzle leakage pipe and gasket.

  7. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A003H7O

      Disconnect the 4 injector connectors.

    2. Remove the 4 bolts and detach the 3 clamps.

    3. A003F57

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

    4. A003C09

      Using a 17 mm union nut wrench, loosen the union nuts and remove the 4 injection pipes.

  8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003EJZE01

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

    2. Disconnect the ventilation hose.

    3. A003D4D

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

    4. A003FOE

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  9. REMOVE INJECTOR ASSEMBLY


    1. A003G52E02

      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 fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A003G9QE01

      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.