FUEL INJECTOR(for Direct Injection) REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

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  3. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Disconnect the fuel pump connector.

    2. A000WD6

      Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the No. 3 fuel pipe sub-assembly from the fuel pump.

      Note

      Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump.

    3. A000U2G

      Remove the 2 bolts on the delivery pipe side and remove the No. 3 fuel pipe sub-assembly.

    4. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe sub-assembly.

  4. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tech Tips

    The removal procedures are the same as for the No. 3 fuel pipe sub-assembly.

  5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    A000V3P

  6. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

    A000TUD

  7. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

    A000V5U

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A000UNKE07
      Text in Illustration
      *1 Union Nut Wrench

      Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub-assembly.

  9. REMOVE FUEL DELIVERY PIPE


    1. A000XG5

      Disconnect the fuel relief valve connector and No. 3 fuel hose.

    2. A000ZGO

      Disconnect the 4 fuel injector connectors.

    3. A00102F

      Remove the 5 bolts and fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  10. REMOVE NO. 2 FUEL DELIVERY PIPE


    1. A000ZAM

      Disconnect the fuel pressure sensor connector.

    2. A000XGK

      Disconnect the 4 fuel injector connectors.

    3. A000VT0

      Remove the 5 bolts and No. 2 fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the No. 2 fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  11. REMOVE FUEL INJECTOR ASSEMBLY


    1. A000YCS

      Secure the fuel delivery pipe between aluminum plates in a vise and pull out the fuel injector assembly in a straight line.

      Note


      • Do not overtighten the vise.

      • Pull and remove the fuel injector assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe's O-ring.

      • For reinstallation, attach a tag or label to the fuel injector assembly shaft.

    2. Remove the nozzle holder clamp from the fuel injector assembly.

    3. Remove the O-ring, No. 1 backup ring, No. 2 backup ring, No. 3 backup ring and E-ring from the fuel injector assembly.

  12. REMOVE FUEL INJECTOR SEAL


    1. A000TNY

      Using the tips of needle-nose pliers, pinch and pull one of the 2 fuel injector seals at several points to stretch it. Repeat this for the other fuel injector seal.

      Note


      • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.

      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.

    2. Remove the 2 fuel injector seals from the fuel injector assembly.

  13. REMOVE FUEL PIPE SUPPORT SUB-ASSEMBLY


    1. A000VQJE04
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 No. 2 Fuel Delivery Pipe

      Remove the 4 bolts and 2 fuel pipe support sub-assemblies.

    2. Remove the 2 O-rings, 2 No. 1 backup rings, 2 No. 2 backup rings and 2 E-rings from the 2 fuel pipe support sub-assemblies.

  14. REMOVE FUEL DELIVERY PIPE PLUG


    1. A000XX3E04
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 No. 2 Fuel Delivery Pipe

      Using a 6 mm hexagon socket wrench, remove the 2 fuel delivery pipe plugs and 2 gaskets from the fuel delivery pipe and No. 2 fuel delivery pipe.