FUEL INJECTOR REMOVAL

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. REMOVE ENGINE ROOM SIDE COVER


    1. A003B3G

      Remove the clip and engine room side cover.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • w/ Navigation System (for HDD):

      After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

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

  3. REMOVE NO. 1 ENGINE COVER


    1. A003DQW

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A00OSNR

      Detach the clamp and disconnect the mass air flow meter connector.

    2. Disconnect the No. 2 ventilation hose.

    3. Disconnect the air cleaner hose.

    4. Detach the 4 clamps and remove the air cleaner cap.

  5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A00OUZE

      Remove the 3 bolts and air cleaner case.

  7. DISCONNECT ENGINE WIRE

    A003BMP

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the grommet and nut and disconnect the glow plug wire harness.

    4. Detach the 2 wire harness clamps.

    5. Remove the bolt and wire harness bracket.

    6. Remove the bolt and 3 nuts and disconnect the engine wire.

  8. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A003DL2

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  9. REMOVE FUEL HOSE PROTECTOR


    1. A003BGR

      Remove the bolt and fuel hose protector.

  10. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A003CV6

      Disconnect the exhaust fuel addition injector connector.

    2. A003BVV

      Turn the retainer as shown in the illustration.

    3. A003BLP

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A003D04E01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    5. Remove the union bolt, gasket and fuel tube.

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A003DSY

      Using pliers, grip the claws of the 3 clips and slide the 3 clips to disconnect the 3 fuel hoses.

    2. A003D2RE01
      Text in Illustration
      *1 Check Valve

      Remove the check valve and gasket.

    3. Remove the bolt and No. 2 nozzle leakage pipe.

  12. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A003D2W

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  13. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A003E8B

      Disconnect the 4 injector connectors.

    2. A003D7U

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

  14. REMOVE INJECTOR ASSEMBLY


    1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

    2. Remove the O-ring from each injector.

      Note

      When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.