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
Replacement of injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

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Battery terminal is disconnected/reconnected Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes) Stop and start system

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Memorize steering angle neutral point Pre-crash safety system

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Note


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

    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

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

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

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • Make sure foreign matter does not enter the fuel path.

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 EGR COOLER SUB-ASSEMBLY AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  4. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o EGR Cooler)

    Click here

  5. REMOVE EGR VALVE ADAPTER SUB-ASSEMBLY (w/o EGR Cooler)

    Click here

  6. CHECK INJECTOR COMPENSATION CODE

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  7. REMOVE NO. 1 FUEL PIPE (w/ DPF)

    Click here

  8. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B00247G

      Disconnect the pressure discharge valve connector from the common rail assembly.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head cover sub-assembly.

  9. REMOVE HARNESS BRACKET


    1. B0024RD

      Remove the bolt and harness bracket.

  10. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. B0027M9

      Slide the clamp and disconnect the No. 5 fuel hose from the nozzle leakage pipe assembly.

    2. Remove the 4 union bolts and 4 gaskets.

    3. Remove the bolt and nozzle leakage pipe assembly.

  11. REMOVE NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the No. 1 and No. 2 injection pipe sub-assemblies, cover the common rail assembly 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. B0028N9E01

      Using SST, loosen the No. 1 and No. 2 injection pipe sub-assemblies and 8 union nuts of the fuel injector assembly side and common rail assembly side.

      SST
      09245-11010
    2. B0027E3

      Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      Note

      When removing the No. 1 injection pipe sub-assembly and No. 2 injection pipe sub-assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.

  12. REMOVE INJECTOR ASSEMBLY


    1. B0028LQ

      Remove the 4 nozzle holder clamp bolts, 4 washers and 4 nozzle holder clamps.

    2. Remove the 4 fuel injector assemblies and 4 injection nozzle seats from the cylinder head sub-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.

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

  13. REMOVE NOZZLE HOLDER GASKET


    1. B0027LW

      Remove the 4 nozzle holder gaskets from the cylinder head cover sub-assembly.