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. 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. 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. 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 No. 1 engine cover to break.

  4. 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. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01ITZL

      Remove the 3 bolts and air cleaner case.

  7. DISCONNECT ENGINE WIRE

    A01IRBA

    1. Disconnect the fuel pressure sensor connector.

    2. Disconnect the pressure discharge valve connector.

    3. Remove the screw 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. 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. REMOVE FUEL HOSE PROTECTOR


    1. A01INWG

      Remove the bolt and fuel hose protector.

  10. REMOVE FUEL TUBE SUB-ASSEMBLY


    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.

      Text in Illustration
      A01ISER Check Valve

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

  11. 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.

      Text in Illustration
      A01ISER Check Valve

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

  12. 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.

  13. 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.

  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 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.