FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Remove the electric EGR control valve assembly Click here.

  3. DISCONNECT INLET HEATER WATER HOSE (w/o EGR System)

    Click here

  4. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  5. REMOVE NO. 1 INTAKE PIPE (w/o EGR System)

    Click here

  6. REMOVE THROTTLE BODY BRACKET (w/o EGR System)

    Click here

  7. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)

    Note


    • After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.

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


    1. B001I3W

      Remove the 2 nuts and No. 3 injection pipe clamp.

    2. B001CH9

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

    3. B001DBGE02
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  8. REMOVE AIR CONNECTOR STAY (w/o EGR System)

    Click here

  9. DISCONNECT ENGINE WIRE (w/o EGR System)

    Click here

  10. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)

    Click here

  11. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE

    Click here

  12. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. B001GUU

      Remove the bolt and detach the injection pipe clamp.

      Note

      If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

    2. B001H5OE06
      Text in Illustration
      *a Injector Side
      *b Common Rail Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  13. REMOVE OIL FILTER SUB-ASSEMBLY

    Click here

  14. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  15. REMOVE VENTILATION PIPE

    Click here

  16. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B001DGN

      Disconnect the 4 injector connectors.

    2. Detach the 2 wire harness clamps and disconnect the wire harness from the No. 2 cylinder head cover.

    3. B001IK8

      Remove the 4 bolts and No. 2 cylinder head cover.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. B001ET3E02

      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. B001CGH

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

    3. B001HEI

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

  18. REMOVE INJECTOR ASSEMBLY


    1. B001GLKE07
      Text in Illustration
      *1 Union Bolt

      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. B001DA1E02

      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.