FUEL INJECTOR (for Direct Injection) REMOVAL


  1. REMOVE INTAKE MANIFOLD

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  2. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. B000I5W

      Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

    2. B000LKK

      Loosen the 2 bolts of the fuel pump with seal sub- assembly.

    3. Remove the No. 1 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly and fuel pump with seal sub- assembly.

  3. DISCONNECT NO. 5 ENGINE WIRE


    1. B000LC8

      Remove the 2 bolts and disconnect the No. 5 engine wire from the fuel delivery pipe sub- assembly.

    2. Disconnect the 4 direct fuel injector assembly connectors.

    3. Disconnect the fuel pressure sensor connector.

  4. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B000JBS

      Remove the 3 bolts, 2 nuts and fuel delivery pipe sub-assembly with the direct fuel injector assemblies.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

      Note


      • Make sure not to touch or strike the tips of the direct fuel injector assemblies.


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

  5. REMOVE DIRECT FUEL INJECTOR ASSEMBLY


    1. B000LF3E01

      Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

      Note


      • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly O-ring.


      • Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.

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

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

    4. Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

    5. Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

  6. REMOVE FUEL INJECTOR SEAL


    1. B000L5W

      Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

      Note


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


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

    2. Remove the fuel injector seal from each direct fuel injector assembly.