FUEL INJECTOR REMOVAL


  1. REMOVE EGR WITH COOLER PIPE ASSEMBLY


    1. Remove the EGR with cooler pipe assembly Click here.

  2. REMOVE NO. 1 EGR COOLER BRACKET


    1. A0117LI

      Disconnect the vacuum hose.

    2. Remove the 2 bolts and No. 1 EGR cooler bracket.

  3. REMOVE NO. 2 INJECTION PIPE CLAMP


    1. A0118OJ

      Remove the nut and both sides of the No. 2 injection pipe clamp.

  4. REMOVE NO. 1 INJECTION PIPE CLAMP


    1. A0119HS

      Remove the 2 nuts and both sides of the No. 1 injection pipe clamp.

  5. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY


    1. A0117KJE01
      Text in Illustration
      *1 No. 1 Injection Pipe
      *2 No. 2 Injection Pipe
      *3 No. 3 Injection Pipe

      Using a union nut wrench (17 mm), separate the union nut from the injector first.

    2. Then remove the union nut from the common rail, and remove the injection pipe.

    3. After removing the injection pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.

  6. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  7. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  8. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A0119AZ

      Remove the 5 screw grommets.

    2. A0116WE

      Remove the nut and disconnect the glow terminal.

    3. Remove the 4 nuts and No. 1 glow plug connector.

  9. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A011AZT

      Remove the No. 2 intake manifold insulator.

  10. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01193I

      Disconnect the 4 injector connectors.

    2. A01171XE01
      Text in Illustration
      *1 Lock Bush

      Pull up the lock bush as shown in the illustration and separate the nozzle leakage pipe.

      Note

      Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.

  11. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01195RE01
      Text in Illustration
      *1 Washer
      *2 Nozzle holder clamp
      *3 Nozzle holder clamp seat

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

  12. REMOVE NOZZLE HOLDER CLAMP SEAT


    1. A0117L1

      Remove the 4 nozzle holder clamp seats from the cylinder head.

  13. REMOVE INJECTOR ASSEMBLY


    1. A011BHC

      Remove the 4 injectors from the cylinder head.

      Tech Tips


      • Each injector assembly has its own fuel injection part number. When replacing the injectors, store them in the correct order so that they can be returned to their original locations when reassembled.

      • Arrange the injectors, clamps, washers, bolts and clamp seats in the correct order.

  14. REMOVE INJECTION NOZZLE SEAT


    1. A011BC0

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

      Tech Tips

      When removing the injector, check that the injector nozzle seat is either attached to the injector, or remains in the cylinder head.