FUEL INJECTOR REMOVAL

PROCEDURE


  1. REMOVE EGR WITH COOLER PIPE ASSEMBLY

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  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE


    1. A005IGW

      Disconnect the mass air flow meter connector.

    2. Disengage the 4 wire harness clamps, and separate the wire harness from the air cleaner cap.

    3. Disengage the 2 lock clamps, disengage the 2 hooks, and then separate the air cleaner cap.

    4. Disconnect the air cleaner hose and remove the air cleaner cap with hose.

  3. REMOVE NO. 1 EGR COOLER BRACKET

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  4. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY


    1. A005J8LE02
      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 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.

  5. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

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

  6. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

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

  7. REMOVE NO. 1 GLOW PLUG CONNECTOR

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  8. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    1. A005JHU

      Remove the No. 2 intake manifold insulator.

  9. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A005M0M

      Disconnect the 4 injector connectors.

    2. A005JFVE01
      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.

  10. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A005LCZE03
      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.

  11. REMOVE NOZZLE HOLDER CLAMP SEAT


    1. A005LS7

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

  12. REMOVE INJECTOR ASSEMBLY


    1. A005H6T

      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.

  13. REMOVE INJECTION NOZZLE SEAT


    1. A005L73

      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.