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. B003VLHC01
      B003U82 Front

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

    2. Remove the No. 2 fuel pipe sub-assembly from the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH.

  3. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

    Note


    • Do not remove the fuel pressure sensor from the fuel delivery pipe with sensor assembly LH.

    • If the fuel pressure sensor is removed, replace the fuel pressure sensor (fuel delivery pipe with sensor assembly LH) with a new one.


    1. B003US1

      Disconnect the fuel pressure sensor connector.

    2. B003THQC01
      B003U82 Front

      Remove the bolt.

    3. Disengage the clamp to disconnect the No. 7 engine wire from the fuel delivery pipe with sensor assembly LH.

    4. B003W88C01
      B003WAF Bolt
      B003U82 Nut
      B003WLN Front

      Remove the 2 bolts and 2 nuts.

    5. B003TYFC01
      B003U82 Front

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the cylinder head LH.

    6. B003UR5C01
      B003U82 Front

      With the connectors still connected, remove the fuel delivery pipe with sensor assembly LH.

      Note


      • Make sure that the fuel delivery pipe is disconnected from the fuel delivery pipe with sensor assembly LH.

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

      • Pull and remove the fuel delivery pipe with sensor assembly LH in a straight line without tilting it.

    7. Disconnect the 3 fuel injector assembly connectors and remove the No. 7 engine wire.

  4. REMOVE FUEL DELIVERY PIPE RH


    1. B003VJSC01
      B003U82 Front

      Remove the bolt.

    2. Disengage the clamp to disconnect the No. 6 engine wire from the fuel delivery pipe RH.

    3. B003W18C01
      B003WAF Bolt
      B003U82 Nut
      B003WLN Front

      Remove the 2 bolts and 2 nuts.

    4. B003UKZC01
      B003U82 Front

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

      Note


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

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

    5. Disconnect the 3 fuel injector assembly connectors and remove the No. 6 engine wire.

  5. REMOVE FUEL INJECTOR ASSEMBLY


    1. B003WZRN01
      *1 No. 2

      Secure the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH 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 damaging the seal surface of the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH O-ring.

      • After removing the fuel injector assemblies, remove any O-rings, No. 1 fuel injector back-up rings and No. 3 fuel injector back-up rings remaining on the fuel delivery pipe with sensor assembly LH and fuel delivery pipe RH side.

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

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

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

      Note

      Do not damage the area that contacts the O-ring.

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

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

  6. REMOVE FUEL INJECTOR SEAL


    1. B003USA

      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 fuel injector assembly.

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

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