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. B0075SLC02
      B0077IM Front Side

      Remove the 4 bolts and No. 3 fuel pipe sub-assembly from the fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly.

      Note

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

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

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


    1. B0075LKC02
      B0077IM Front Side

      Disengage the 3 clamps to disconnect the No. 7 engine wire.

    2. B0075YNC02
      B0073AQ Nut
      B0077IM Bolt
      B0077LI Front Side

      Remove the 2 bolts and 2 nuts.

    3. B0073A0C03
      B0077IM Front Side

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

      Note


      • Make sure to disconnect the No. 2 fuel delivery pipe sub-assembly first when disconnecting the fuel delivery pipe sub-assembly and No. 2 fuel delivery pipe sub-assembly.

      • Make sure not to touch or strike the tips of the fuel injector assembly.

      • Pull and remove the No. 2 fuel delivery pipe sub-assembly 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. B0076ML

      Disconnect the fuel pressure sensor connector.

    2. Disengage the clamp to disconnect the wire harness.

    3. B0072NJC02
      B0077IM Front Side

      Disengage the 2 clamps to disconnect the No. 6 engine wire.

    4. B00757SC03
      B0073AQ Nut
      B0077IM Bolt
      B0077LI Front Side

      Remove the 2 bolts and 2 nuts.

    5. B0074C9C01
      B0077IM Front Side

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

      Note


      • Make sure 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.

    6. Disconnect the 3 fuel injector assembly connectors.

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

  5. REMOVE FUEL INJECTOR ASSEMBLY


    1. B0076FON04
      *1 NO. 2

      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 damaging 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. B00752M

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

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