FUEL INJECTOR (for DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  2. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

    Click here

  3. CHECK INJECTOR COMPENSATION CODE

    Tech Tips

    If the injector compensation code is not correctly registered, it may cause malfunctions.


    1. Read the injector compensation code Click here.

    2. Check that the compensation code of the installed injector is the same as the code registered in the ECM. If the code is not the same, register the injector compensation code on the injector Click here.

  4. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DW4L

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01E26N

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  5. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01DV6CE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Wiring Harness Clamp Bracket

      Detach the wire harness clamp.

    2. Remove the bolt and wiring harness clamp bracket.

  6. REMOVE NO. 2 FUEL PIPE


    1. A01E2AW

      Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Supply Pump Hollow Screw
      A01E01H Fuel Check Valve
      A01DXHC Union Bolt

    2. Remove the fuel check valve, union bolt and 2 gaskets.

    3. Remove the 3 bolts and No. 2 fuel pipe.

  7. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DZSF

      Disconnect the 3 fuel hoses.

      Text in Illustration
      A01DZ8Z Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  8. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01E159

      Remove the 2 bolts.

      Text in Illustration
      A01DZ8Z Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.

  9. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DYAV

      Remove the 3 bolts and No. 2 cylinder head cover.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. A01DXC5E01

      Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.

    2. Disconnect the ventilation hose.

    3. A01DYWG

      Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.

    4. A01DV31

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  11. REMOVE INJECTOR ASSEMBLY


    1. A01DZ18E04
      Text in Illustration
      *1 Union Bolt

      Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.

      Note


      • When removing the nozzle leakage pipe, place a cushion under the pipe.

      • Be careful not to deform or scratch the union seal surface.

      • After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

    2. A01E2JYE02

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

      Tech Tips

      Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.

    3. Remove the O-ring from each injector.

    4. Remove the 4 injection nozzle seats from the cylinder head.