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FUEL INJECTOR REMOVAL

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Note:

  • After the engine has stopped, wait at least 1 minute before releasing the high pressure lines.

  • When working on the fuel circuit, protect the generator assembly against dirt contamination.

    Cover the generator assembly with suitable materials.

    Failure to comply with this procedure may result in a generator assembly malfunction.

  • A01IPPME01

    After disconnecting the pressure line, it is absolutely essential to seal the injector assemblies and the common rail assembly with SST.

    SST
    PZ4TB-04941-79
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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. A01IRDDE01

      Lift the No. 1 engine cover to detach the 4 clips in the order shown in the illustration 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. Click here

    REMOVE ENGINE COVER

  5. Click here

    REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note:

    Reset SST in a timely manner to prevent bending of pressure lines.


    1. Using SST, loosen the 4 union nuts at the common rail assembly end of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST
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    2. Using SST, loosen the 4 union nuts at the 4 injector assembly ends of the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

      SST
      PZ4TB-04959-10

    3. Remove the 2 No. 1 injection pipe sub-assemblies and 2 No. 2 injection pipe sub-assemblies.

  6. Click here

    REMOVE CAMSHAFT POSITION SENSOR


    1. A01IUP4

      Disconnect the camshaft position sensor connector.

    2. Using an E6 "TORX" socket wrench, remove the bolt and camshaft position sensor.

  7. Click here

    DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01IQZ7

      Disconnect the connector and detach the 2 clamps to disconnect the wire harness (Click here).

    2. Disconnect the nozzle leakage pipe assembly and remove the 4 sealing rings.


      1. A01IQKKE01

        Press in the clamp.

        Table 1. Text in Illustration
        *1 Sealing Ring
        *2 Leakage Line
        *3 Clamp
        *4 Rubber Grommet
        *a Press
        *b Upward
        Note:

        If a sealing ring is damaged, the entire leakage line of a cylinder group must be replaced.

      2. Detach the connection of the nozzle leakage pipe assembly upwards.

      3. Remove the sealing ring.

      4. Disconnect the nozzle leakage pipe assembly from the rubber grommet.

  8. Click here

    REMOVE INJECTOR ASSEMBLY


    1. A01ISRF

      Disconnect the 4 injector assembly connectors.

    2. A01IRX9

      Using an E10 "TORX" socket wrench, remove the 4 bolts and 4 centering rings.

    3. Remove the 4 clamping claws from the 4 injector assemblies.

    4. A01ITN6E01

      Remove the 4 injector assemblies from the cylinder head cover sub-assembly.


      1. Pull out the injector assembly with light rotational movements.

        SST
        PZ4TB-04942-79
        Tip:

        • If an injector assembly is stuck tight, mount SST (rod) to the pressure line connection.

        • Move injector assembly with SST (rod) only by a few degrees.