FUEL INJECTOR REMOVAL

CAUTION / NOTICE / HINT

Note:

  • When replacing the injector assemblies (including shuffling the injector assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.

PROCEDURE

  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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE NO. 1 ENGINE COVER

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  4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  6. REMOVE AIR CLEANER CASE

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  7. DISCONNECT ENGINE WIRE

    1. A271556

      Remove the bolt from the wire harness bracket.

    2. A271557

      Disconnect the fuel temperature sensor connector and suction control valve connector.

    3. A271559

      Disconnect the engine coolant temperature sensor.

    4. A271561

      Detach the clamp and remove the bolt and fuel hose protector.

    5. A271562

      Disconnect the exhaust fuel addition injector connector.

    6. A271197

      Disconnect the No. 1 vacuum switching valve connector and vacuum regulating valve connector.

    7. A271564

      Disconnect the 4 fuel injector connectors.

    8. A271195

      Remove the No. 1 screw grommet and nut, and disconnect the glow plug wire harness.

    9. Disconnect the fuel pressure sensor connector and electric EGR control valve connector.

    10. A271566

      Disconnect the diesel turbo pressure sensor connector.

    11. A271567

      Disconnect the pressure discharge valve connector.

    12. A271568

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

  8. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note:

    After removing the injection pipe, cover the common rail with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also, protect the injector inlets with electrical tape or plastic bags.

    1. A271569

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

    2. A271570

      Using a 14 mm union nut wrench, loosen the 8 union nuts and remove the 4 injection pipe sub-assemblies.

  9. REMOVE FUEL HOSE PROTECTOR

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  10. REMOVE FUEL TUBE SUB-ASSEMBLY

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  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE

    1. A271573

      Slide the 3 clamps and disconnect the No. 2 fuel hose, No. 3 fuel hose and No. 4 fuel hose from the No. 2 nozzle leakage pipe.

    2. A271574C02

      *1

      Check Valve

      Remove the check valve and gasket.

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

  12. REMOVE NO. 1 NOZZLE LEAKAGE PIPE

    1. A271575

      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. A271576

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

  14. REMOVE INJECTOR ASSEMBLY

    1. Remove the 4 injector assemblies and 4 injection nozzle seats from the cylinder head sub-assembly.

    2. Remove the O-ring from each injector assembly.

      Note:

      When removing the injector assembly, store the injector assemblies in the correct order so that they can be returned to their original locations when reassembling.