FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the injector assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

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CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B003Q0P

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

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 INTERCOOLER ASSEMBLY

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  4. CHECK INJECTOR COMPENSATION CODE

    Tech Tips

    If the injector compensation code is not correctly registered, it may cause malfunctions.


    1. Read the injector compensation code.

      Click here

    2. Check that the compensation code of the installed injector assembly is the same as the code registered in the ECM. If the code is not the same, register the injector compensation code on the injector assembly.

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  5. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 3 injection pipe sub-assembly, cover the outlets on the common rail assembly with tape to keep out foreign matter.

    • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 3 injection pipe sub-assembly, put it in a plastic bag to prevent foreign matter from contaminating its injector assembly inlet.


    1. B003QCNC01
      *1 No. 2 Injection Pipe Clamp
      *2 No. 3 Injection Pipe Clamp

      Remove the bolt and No. 2 injection pipe clamp from the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly.

    2. Remove the 2 nuts and No. 3 injection pipe clamp from the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 3 injection pipe sub-assembly.

    3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and No. 3 injection pipe sub-assembly from the injector assembly and common rail assembly.

  6. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note

    If an injection pipe clamp is removed from the No. 4 injection pipe sub-assembly, replace the injection pipe clamp with a new one.


    1. B003OQG

      Remove the 2 bolts and disconnect the 2 injection pipe clamps from the intake manifold.

    2. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe sub-assembly from the injector assembly and common rail assembly.

  7. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B003JFCC01
      *1 Fuel Hose
      *2 No. 1 Fuel Hose
      *3 No. 2 Fuel Hose
      B003LF2 Union Bolt

      Slide the 3 clamps and disconnect the fuel hose, No. 1 fuel hose and No. 2 fuel hose from the No. 2 nozzle leakage pipe assembly.

    2. Remove the union bolt, 2 bolts, No. 2 nozzle leakage pipe assembly and gasket from the intake manifold and cylinder head sub-assembly.

  8. DISCONNECT ENGINE WIRE


    1. for LHD:


      1. B003L91

        Disconnect the connector from the diesel throttle body assembly.

      2. Disconnect the 4 connectors from the 4 injector assemblies.

      3. Disconnect the connector from the engine coolant temperature sensor.

      4. Disconnect the connector from the compressor assembly.

      5. Remove the 3 bolts.

      6. Detach the 3 clamps and disconnect the engine wire from the cylinder head cover sub-assembly.

    2. for RHD:


      1. B003OH3

        Disconnect the connector from the diesel throttle body assembly.

      2. Disconnect the 4 connectors from the 4 injector assemblies.

      3. Disconnect the connector from the engine coolant temperature sensor.

      4. Disconnect the connector from the compressor assembly.

      5. Remove the 3 bolts.

      6. Detach the clamp and disconnect the engine wire from the cylinder head cover sub-assembly.

  9. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover sub-assembly is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. Disconnect the PCV hose from the cylinder head cover sub-assembly.

    2. B003NNUC01
      *a Cutout Part

      Using a small screwdriver, remove the 4 nozzle holder seals by prying between the nozzle holder seal and the cutout part of the cylinder head cover sub-assembly.

    3. B003OXN

      Remove the 10 bolts, 2 nuts, cylinder head cover sub-assembly and cylinder head cover gasket from the cylinder head sub-assembly.

    4. B003QZE

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

  10. REMOVE INJECTOR ASSEMBLY


    1. B003RZWC01
      B003LF2 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe assembly from the injector assembly and cylinder head sub-assembly.

      Note


      • When removing the nozzle leakage pipe assembly, place a cushion under the nozzle leakage pipe assembly.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe assembly, put it in a plastic bag to prevent foreign matter from contaminating its injector assembly inlet.

    2. B003QJA

      Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injector assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the injector assemblies, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector assembly.

    4. Remove the 4 injection nozzle seats from the cylinder head sub-assembly.