FUEL INJECTOR REMOVAL

PROCEDURE

1. PRECAUTION

   Note

   After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work.

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2. DISCHARGE FUEL SYSTEM PRESSURE

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3. REMOVE BATTERY BOX COVER

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4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

   Note

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

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5. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY

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6. DISCONNECT ENGINE WIRE

   

   
   

   1. Disconnect the 4 fuel injector connectors.

   2. Disconnect the 4 connectors.

   3. Remove the bolt.

   4. Disengage the 2 clamps to disconnect the wire harness.

7. DISCONNECT FUEL TUBE SUB-ASSEMBLY

   
   

   1. 

      Disengage the claw and remove the No. 1 fuel pipe clamp.

   2. 

      *a	Fuel Pipe
      *b	Fuel Tube Connector
      *c	Nylon Tube
      *d	O-ring
      *e	Retainer
      	Pinch
      	Pull

      Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

      Note

      
      

      • Check for foreign matter on the fuel tube around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-rings to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

      • Cover the fuel tube connector and fuel pipe with plastic bags to prevent damage and contamination.

8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

   
   

   1. 

      Remove the bolt.

   2. 

      Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

9. REMOVE NO. 1 DELIVERY PIPE SPACER

   
   

   1. 

      Remove the 2 No. 1 delivery pipe spacers from the cylinder head.

10. REMOVE FUEL INJECTOR ASSEMBLY

    
    

    1. 

       Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

    2. Remove the O-ring from each fuel injector assembly.

    3. For reinstallation, attach a tag or label with the corresponding cylinder number to each fuel injector assembly shaft.

       Note

       Protect the fuel injector assemblies by covering them with plastic bags.

    4. 

       Remove the 4 injector vibration insulators.