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FUEL INJECTOR REMOVAL

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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.

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  1. Click here

    PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).

  2. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

  3. Click here

    REMOVE NO. 1 ENGINE COVER


    1. A01INMI

      Hold the rear of the No. 1 engine cover and slowly raise it to detach the clip on the rear of the No. 1 engine cover. Continue to raise the No. 1 engine cover to detach the 3 clips on the front and side of the No. 1 engine cover and remove the No. 1 engine cover.

      Note:

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

  4. Click here

    REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01IOT2

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

    2. Slide the clamp and disconnect the PCV hose from the cylinder head cover sub-assembly.

    3. Slide the clamp and disconnect the air cleaner hose assembly from the turbocharger sub-assembly.

    4. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  5. Click here

    REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. Click here

    REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01ITZL

      Remove the 3 bolts and air cleaner case.

  7. Click here

    DISCONNECT ENGINE WIRE


    1. Disconnect the fuel pressure sensor connector and the pressure discharge valve connector.

    2. Detach the 2 wire harness clamps.

    3. Remove the bolt and wire harness bracket.

    4. A01IQTI

      for DPF:


      1. Disconnect the glow plug connector.

      2. Disconnect the 3 connectors.

      3. Remove the 2 bolts and 5 nuts and disconnect the engine wire.

    5. A01IRBA

      for CCo:

      Remove the screw grommet and nut, and disconnect the glow plug wire harness.


      1. Remove the screw grommet and nut, and disconnect the glow plug wire harness.

      2. Remove the bolt and 3 nuts, and disconnect the engine wire.

  8. Click here

    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. A01IO2G

      Remove the 2 bolts and 4 No. 2 injection pipe clamps.

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

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

    4. Remove the 4 injection pipes.

  9. Click here

    REMOVE FUEL HOSE PROTECTOR (for DPF)


    1. A01INWG

      Remove the bolt and fuel hose protector.

  10. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. A01IT57

      Disconnect the exhaust fuel addition injector connector.

    2. A01IQ6B

      Turn the retainer as shown in the illustration.

    3. A01IUL8

      Disconnect the fuel tube sub-assembly from the exhaust fuel addition injector assembly.

    4. A01INMW

      Remove the check valve and gasket.

      Table 1. Text in Illustration
      A01ISER Check Valve

    5. Remove the union bolt, gasket and fuel tube sub-assembly.

  11. Click here

    REMOVE NO. 2 FUEL PIPE (for CCo)


    1. A01IN5Z

      Remove the check valve and gasket.

      Table 2. Text in Illustration
      A01ISER Check Valve

    2. Remove the union bolt, gasket and No. 2 fuel pipe.

  12. Click here

    REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01ITZX

      Slide the 3 clips and disconnect the 3 fuel hoses from the No. 2 fuel hose, No. 3 fuel hose and No. 4 fuel hose.

    2. A01IPB2

      Remove the check valve and gasket.

      Table 3. Text in Illustration
      A01ISER Check Valve

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

  13. Click here

    REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A01ISVS

      Remove the 4 union bolts and 4 gaskets.

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

  14. Click here

    REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01INU7

      Disconnect the 4 injector connectors.

    2. A01IRLW

      Remove the 4 bolts, 4 washers and 4 No. 1 nozzle holder clamps.

  15. Click here

    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 assembly.

      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.