FUEL INJECTOR(for Direct Injection) REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. 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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  4. REMOVE INTAKE MANIFOLD

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  5. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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  6. DISCONNECT SENSOR WIRE


    1. B0077LC

      Disconnect the fuel pressure sensor connector.

    2. Remove the 2 bolts to disconnect the sensor wire from the fuel delivery pipe sub-assembly.

    3. B0077Z8

      Disconnect the 4 direct fuel injector assembly connectors.

  7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B0075ZJC03
      B0073AQ Bolt
      B0077IM Nut

      Remove the 3 bolts, 2 nuts and fuel delivery pipe sub-assembly with the direct fuel injector assemblies.

      Note


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

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

  8. REMOVE DIRECT FUEL INJECTOR ASSEMBLY


    1. B0077VON01
      *1 No. 2

      Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

      Note


      • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly O-ring.

      • After removing the direct 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 sub-assembly side.

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

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

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

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

  9. REMOVE FUEL INJECTOR SEAL


    1. B0076RB

      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 direct fuel injector assembly.

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

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