CAUTION / NOTICE / HINT
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.
PROCEDURE
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.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE NO. 1 ENGINE COVER
REMOVE AIR CLEANER CAP SUB-ASSEMBLY
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
DISCONNECT ENGINE WIRE
Disconnect the fuel pressure sensor connector.
Disconnect the pressure discharge valve connector.
Remove the grommet and nut and disconnect the glow plug wire harness.
Detach the 2 wire harness clamps.
Remove the bolt and wire harness bracket.
Remove the bolt and 3 nuts and disconnect the engine wire.
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.
Remove the 2 bolts and 4 injection pipe clamps.
Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.
Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.
Remove the 4 injection pipes.
REMOVE FUEL HOSE PROTECTOR
REMOVE FUEL TUBE SUB-ASSEMBLY
REMOVE NO. 2 NOZZLE LEAKAGE PIPE
Disconnect the 3 fuel hoses.
Remove the check valve and gasket.
Check Valve |
Remove the bolt and No. 2 nozzle leakage pipe.
REMOVE NO. 1 NOZZLE LEAKAGE PIPE
Remove the 4 union bolts and 4 gaskets.
Remove the bolt and No. 1 nozzle leakage pipe.
REMOVE NO. 1 NOZZLE HOLDER CLAMP
Disconnect the 4 injector connectors.
Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.
REMOVE INJECTOR ASSEMBLY
Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.
Remove the O-ring from each injector.
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.