PROCEDURE
REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY
REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE
Disconnect the mass air flow meter connector.
Disengage the 4 wire harness clamps, and separate the wire harness from the air cleaner cap.
Disengage the 2 lock clamps, disengage the 2 hooks, and then separate the air cleaner cap.
Disconnect the air cleaner hose and remove the air cleaner cap with hose.
REMOVE NO. 1 EGR COOLER BRACKET
REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY
*1 | No. 1 Injection Pipe |
*2 | No. 2 Injection Pipe |
*3 | No. 3 Injection Pipe |
Using a union nut wrench (17 mm), separate the union nut from the injector first.
Then remove the union nut from the common rail, and the injection pipe.
After removing the injection pipe, cover the common rail with vinyl tape and cover the injector inlet with a vinyl or plastic bag in order to prevent dust and foreign matter from entering.
REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY
Tech Tips
Perform the same procedure as for No. 1 injection pipe.
REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY
Tech Tips
Perform the same procedure as for No. 1 injection pipe.
REMOVE NO. 1 GLOW PLUG CONNECTOR
REMOVE NO. 2 INTAKE MANIFOLD INSULATOR
Remove the No. 2 intake manifold insulator.
REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY
Disconnect the 4 injector connectors.
*1 | Lock Bush |
Pull up the lock bush as shown in the illustration and separate the nozzle leakage pipe.
Note
Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.
REMOVE NO. 1 NOZZLE HOLDER CLAMP
*1 | Washer |
*2 | Nozzle holder clamp |
*3 | Nozzle holder clamp seat |
Remove the 4 bolts, 4 washers, and 4 nozzle holder clamps.
REMOVE NOZZLE HOLDER CLAMP SEAT
Remove the 4 nozzle holder clamp seats from the cylinder head.
REMOVE INJECTOR ASSEMBLY
Remove the 4 injectors from the cylinder head.
Tech Tips
Each injector assembly has its own fuel injection part number. When replacing the injectors, store them in the correct order so that they can be returned to their original locations when reassembled.
Arrange the injectors, clamps, washers, bolts and clamp seats in the correct order.
REMOVE INJECTION NOZZLE SEAT
Remove the 4 injection nozzle seats from the injector or cylinder head.
Tech Tips
When removing the injector, check that the injector nozzle seat is either attached to the injector or remains in the cylinder head.