FUEL INJECTOR(for Direct Injection) REMOVAL

PROCEDURE


  1. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  2. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. A000P66

      Loosen the 2 union nuts and remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe.

      Text in Illustration
      B002BBR Front

  3. REMOVE FUEL DELIVERY PIPE LH


    1. A000ONV

      Remove the bolt and detach the 2 wire harness clamps.

      Text in Illustration
      B002BBR Front
    2. A000OBYE01
      Text in Illustration
      *1 Bolt
      *2 Nut
      *a Front

      Remove the 2 bolts and 2 nuts.

    3. A000R6H

      With the connectors still connected, disconnect the fuel delivery pipe LH.

      Text in Illustration
      B002BBR Front

      Note


      • Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).

      • Be extremely careful not to touch or strike the tips of the injectors.

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

    4. Disconnect the 3 injector connectors.

  4. REMOVE FUEL DELIVERY PIPE RH


    1. A000NKG

      Disconnect the fuel pressure sensor connector.

      Note

      Do not pull the wire harness of the fuel pressure sensor excessively.

    2. A000OIX

      Remove the bolt and detach the wire harness clamp.

      Text in Illustration
      B002BBR Front
    3. A000SHUE01
      Text in Illustration
      *1 Bolt
      *2 Nut
      *a Front

      Remove the 2 bolts and 2 nuts.

    4. A000SCE

      With the connectors still connected, disconnect the fuel delivery pipe RH.

      Text in Illustration
      B002BBR Front

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

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

    5. Disconnect the 3 injector connectors.

  5. REMOVE FUEL INJECTOR ASSEMBLY


    1. A000NACE02
      *1 NO.1

      Fix the fuel delivery pipe in a vise between aluminum plates.

      Note


      • Do not tighten the vise more than necessary.

      • Do not damage the fuel injector assemblies.

    2. Remove the fuel injector assemblies from the fuel delivery pipe LH and fuel delivery pipe RH.

      Note


      • When removing an injector, pull the injector straight out to avoid damaging the O-ring seal surfaces of the fuel delivery pipe LH and fuel delivery pipe RH.

      • After removing the injector, check that the O-ring, No. 1 fuel injector back-up ring and No. 3 fuel injector back-up ring are not remaining on the fuel delivery pipe. If any of the parts remain on the fuel delivery pipe, remove them.

      • Attach a label to the removed injector assembly to distinguish it from other cylinders.

    3. Remove the nozzle holder clamps from the injectors.

    4. Using needle-nose pliers, remove the No. 3 fuel injector back-up ring from the injector assembly.

      Note

      Do not damage the part contacting the O-ring.

    5. Remove the O-ring and No. 1 fuel injector back-up ring.

    6. Remove the C-rings and injector vibration insulators from the injectors.

  6. REMOVE FUEL INJECTOR SEAL


    1. A000Q1A

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

      Note


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

      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

    2. Remove the injector seal from the injector.