FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

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 EGR COOLER ASSEMBLY

    Click here

  4. CHECK INJECTOR COMPENSATION CODE

    Click here

  5. REMOVE NO. 1 FUEL PIPE

    Click here

  6. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B001GDN

      Disconnect the pressure discharge valve connector from the common rail assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  7. REMOVE HARNESS BRACKET


    1. B001FIH

      Remove the bolt and harness bracket.

  8. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B001FI6

      Slide the clamp and disconnect the No. 5 fuel hose from the nozzle leakage pipe assembly.

    2. Remove the 4 union bolts and 4 gaskets.

    3. Remove the bolt and nozzle leakage pipe assembly.

  9. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.


    1. B001CXPE02

      Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

      SST
      09245-11010
    2. B001I6V

      Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      Note

      When removing the No. 1 injection pipe subassembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

  10. REMOVE INJECTOR ASSEMBLY


    1. B001FQF

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

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

      Note

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

    3. Remove the O-ring from each injector assembly.

  11. REMOVE NOZZLE HOLDER GASKET


    1. B001DUX

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.