FUEL INJECTOR REMOVAL

PROCEDURE

  1. PRECAUTION

    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 contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

    • A316354N01

      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

    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices 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 ENGINE COVER

    1. A314051

      Remove the engine cover.

  5. REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note:

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

    1. A355158N01

      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

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

  6. REMOVE CAMSHAFT POSITION SENSOR

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  7. DISCONNECT NOZZLE LEAKAGE PIPE ASSEMBLY

    1. A314053

      Disconnect the connector and detach the 2 clamps to disconnect the wire harness.

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    2. A340051C01

      *1

      Sealing Ring

      *a

      Leakage Line

      *b

      Clip

      *c

      Pull up

      Pull up the 4 clips and disconnect the nozzle leakage pipe assembly from the 4 injector assemblies as shown in the illustration.

      Note:

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

    3. Remove the 4 sealing rings from the nozzle leakage pipe assembly.

  8. REMOVE INJECTOR ASSEMBLY

    1. A314055

      Disconnect the 4 injector assembly connectors.

    2. A314056

      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. A314060N01

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

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

        SST

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        Tip:

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

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