FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

Note


  • When replacing the injector assemblies (including shuffling the injector assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.

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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  3. REMOVE NO. 1 ENGINE COVER

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  4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE

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  7. DISCONNECT ENGINE WIRE


    1. A01V7JX

      Remove the bolt from the wire harness bracket.

    2. A01V86R

      Disconnect the fuel temperature sensor connector and suction control valve connector.

    3. A01VAXZ

      Disconnect the engine coolant temperature sensor.

    4. A01V6Z4

      for DPF:

      Detach the clamp and remove the bolt and fuel hose protector.

    5. A01V72E

      for DPF:

      Disconnect the exhaust fuel addition injector connector.

    6. A01V7U4

      Disconnect the No. 1 vacuum switching valve connector and vacuum regulating valve connector.

    7. A01V7J6

      Disconnect the 4 fuel injector connectors.

    8. A01V6SF

      Remove the No. 1 screw grommet and nut, and disconnect the glow plug wire harness.

    9. Disconnect the fuel pressure sensor connector and electric EGR control valve connector.

    10. A01VA65

      Disconnect the diesel turbo pressure sensor connector.

    11. A01V8P1

      Disconnect the pressure discharge valve connector.

    12. A01V7KZ

      Remove the 2 bolts and 5 nuts and disconnect the engine wire.

  8. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, cover the common rail 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. A01VAZQ

      Remove the 2 bolts and 4 No. 2 injection pipe clamps.

    2. A01VAO3

      Using a 14 mm union nut wrench, loosen the 8 union nuts and remove the injection pipe sub-assemblies.

  9. REMOVE FUEL HOSE PROTECTOR (for DPF)

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  10. REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)

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  11. REMOVE NO. 2 FUEL PIPE (for CCo)

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  12. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01VAJB

      Slide the 3 clamps and disconnect the No. 2 fuel hose, No. 3 fuel hose and No. 4 fuel hose from the No. 2 nozzle leakage pipe.

    2. A01V8M4C02
      *1 Check Valve

      Remove the check valve and gasket.

    3. Remove the bolt and No. 2 nozzle leakage pipe.

  13. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A01VA66

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  14. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01V6RB

      Remove the 4 nozzle holder clamp bolts, 4 washers and 4 No. 1 nozzle holder clamps.

  15. REMOVE INJECTOR ASSEMBLY


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

    2. Remove the O-ring from each injector 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.