FUEL INJECTOR(for Direct Injection) REMOVAL

PROCEDURE


  1. REMOVE FUEL PUMP ASSEMBLY

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  2. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. B003X0UC01
      B003U82 Front

      Remove the 4 bolts and No. 3 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly.

      Note

      Pull and remove the No. 3 fuel pipe sub-assembly in a straight line to avoid damage to the seal surface of the delivery pipe O-rings.

    2. Remove the 2 O-rings, No. 1 back-up ring, No. 2 back-up ring, No. 3 back-up ring and 2 E-rings from the No. 3 fuel pipe sub-assembly.

  3. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B003U8EC01
      B003U82 Front Side

      Disconnect the 3 wire harness clamps.

    2. B003X0PC02
      B003WAF Nut
      B003U82 Bolt
      B003WLN Front Side

      Remove the 2 bolts and 2 nuts.

    3. B003TU1C02
      B003U82 Front Side

      With the connectors still connected, disconnect the No. 2 fuel delivery pipe sub-assembly.

      Note


      • Make sure that the fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly are disconnected from the No. 2 fuel delivery pipe sub-assembly.

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

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

    4. Disconnect the 3 fuel injector assembly connectors.

    5. Remove the 3 injector vibration insulators from the cylinder head sub-assembly.

  4. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B003VAI

      Disconnect the fuel pressure sensor connector and wire harness clamp.

    2. B003TTCC02
      B003U82 Front Side

      Disengage the 2 wire harness clamps.

    3. B003T20C03
      B003WAF Nut
      B003U82 Bolt
      B003WLN Front Side

      Remove the 2 bolts and 2 nuts.

    4. B003UFUC01
      B003U82 Front Side

      With the connectors still connected, disconnect the fuel delivery pipe sub-assembly.

      Note


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

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

    5. Disconnect the 3 fuel injector assembly connectors.

    6. Remove the 3 injector vibration insulators from the cylinder head sub-assembly.

  5. REMOVE FUEL INJECTOR ASSEMBLY


    1. B003VE1N03
      *1 NO.1

      Secure the fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 6 fuel injector assemblies.

      Note


      • Pull and remove each fuel injector assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly O-ring.

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

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

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

  6. REMOVE FUEL INJECTOR SEAL


    1. B003T0S

      Using the tip of needle nose pliers, pinch and pull either 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 a fuel injector assembly is struck, replace it with a new one.

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