FUEL INJECTOR (w/ DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the engine 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 Click here.

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

  2. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  3. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  4. DISCONNECT WIRE HARNESS


    1. A00JYTX

      Remove the bolt and disconnect the wire harness.

    2. A00K074

      for LHD:

      Remove the bolt and disconnect the wire harness.

    3. Detach the 5 clamps and disconnect the wire harness from the cowl top panel.

  5. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A00JZBI

      Disconnect the manifold absolute pressure sensor connector and vacuum hose.

    2. Remove the bolt and manifold absolute pressure sensor.

  6. REMOVE EMISSION CONTROL VALVE BRACKET


    1. A00JW2S

      Remove the bolt and emission control valve bracket.

  7. REMOVE THROTTLE BODY BRACKET


    1. A00K044

      Remove the 3 bolts and throttle body bracket.

  8. REMOVE NO. 1 GAS FILTER


    1. A00JZLL

      Disconnect the vacuum hose and remove the No. 1 gas filter from the gas filter bracket.

  9. REMOVE GAS FILTER BRACKET


    1. A00K1HA

      Detach the clamp and disconnect the wire harness.

    2. A00K059

      Remove the bolt and gas filter bracket.

  10. REMOVE INTAKE AIR CONNECTOR


    1. A00JWYM

      Remove the 3 bolts, intake air connector and gasket.

  11. REMOVE NO. 1 FUEL PIPE


    1. Disconnect the No. 2 fuel pipe Click here.

    2. Remove the 4 bolts, union bolt, gasket and No. 1 fuel pipe.

      A00XH74E01
      Text in Illustration
      *1 No. 2 Fuel Pipe - -
      A00XFQT Union Bolt - -

  12. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A00XCX9

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A00XCYIE01
      Text in Illustration
      *a Common Rail Side
      *b Injector Side

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  13. REMOVE NO. 2 FUEL PIPE


    1. A00XIX4

      Using a 6 mm hexagon wrench, remove the union bolt and gasket.

      Text in Illustration
      A00XHOQ Union Bolt
      A00XFQT Fuel Check Valve

    2. Remove the fuel check valve, gasket and No. 2 fuel pipe.

  14. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A00XGZK

      Disconnect the 2 fuel hoses.

      Text in Illustration
      A00XFQT Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  15. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00XET4

      Remove the 3 bolts.

      Text in Illustration
      A00XFQT Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.

  16. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00XEDI

      Remove the 4 bolts and No. 2 cylinder head cover.

  17. REMOVE VENTILATION PIPE


    1. A00JWRJ

      Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

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


    1. A00XD84E01

      Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.

    2. A00XH2E

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    3. A00XCKH

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  19. REMOVE INJECTOR ASSEMBLY


    1. A00XFVDE04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


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

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

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

    2. A00XDIKE02

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

      Tech Tips

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

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.