FUEL INJECTOR REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. REMOVE REAR NO. 2 FLOOR BOARD

    Click here

  4. REMOVE REAR DECK FLOOR BOX

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  5. REMOVE REAR NO. 3 FLOOR BOARD

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  6. REMOVE DECK FLOOR BOX RH

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  7. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE

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  8. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  9. REMOVE RADIATOR SUPPORT OPENING COVER (w/o EGR System)

    Click here

  10. REMOVE NO. 2 CYLINDER HEAD COVER (w/o EGR System)

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  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (w/o EGR System)

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  12. REMOVE WATER HOSE HOSE CLAMP (w/o EGR System)

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  13. REMOVE INLET AIR CLEANER ASSEMBLY (w/o EGR System)

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  14. REMOVE AIR CLEANER CASE (w/o EGR System)

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  15. REMOVE AIR CLEANER HOSE ASSEMBLY (w/o EGR System)

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  16. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY (w/ EGR System)

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  17. DISCONNECT ENGINE WIRE

    B001N7Z

    1. Disconnect the 4 fuel injector connectors.

    2. Disconnect the 4 connectors.

    3. Remove the bolt.

    4. Disengage the 2 clamps to disconnect the engine wire.

  18. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B001MCP

      Disengage the claw and remove the No. 1 fuel pipe clamp.

    2. B001KBO

      Pinch the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

      Note


      • Check for foreign matter on the fuel tube sub-assembly around the fuel tube connector. Clean if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcibly bend, kink or twist the fuel tube sub-assembly.

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

      • Cover the fuel tube connector with a plastic bag to prevent damage and contamination.

  19. SEPARATE NO. 1 WATER BY-PASS PIPE (w/o EGR System)


    1. B001M4X

      Disengage the clamp to disconnect the engine wire.

    2. Remove the 2 bolts and nut, and separate the No. 1 water by-pass pipe.

  20. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B001LVW

      Remove the bolt.

    2. B001N4A

      Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

  21. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. B001KZJ

      Remove the 2 No. 1 delivery pipe spacers from the cylinder head.

  22. REMOVE FUEL INJECTOR ASSEMBLY


    1. B001N5Z

      Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

    2. Remove the O-ring from each fuel injector assembly.

    3. For reinstallation, attach a tag or label with the corresponding cylinder number to each fuel injector shaft.

      Note

      Protect the fuel injector assemblies by covering them with plastic bags.

    4. B001LDJ

      Remove the 4 injector vibration insulators.