FUEL INJECTOR(w/o Glow Plug Controller) REMOVAL

CAUTION / NOTICE / HINT

Note:

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

Tip:

After replacing any of the injector assemblies, perform both the "Injector Compensation" and the "Pilot Quantity Learning Values Reset" functions using the GTS.

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PROCEDURE

  1. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY

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  2. REMOVE NO. 1 EGR COOLER BRACKET

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  3. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Note:

    After removing the injection pipe sub-assembly, cover the common rail assembly with protective tape to prevent dirt or foreign matter from entering the pipe inlet. Also protect the injector inlets by covering them with protective tape or plastic bags.

    1. A211264C01

      *1

      No. 1 Injection Pipe Sub-assembly

      *2

      No. 2 Injection Pipe Sub-assembly

      *3

      No. 3 Injection Pipe Sub-assembly

      Using a 17 mm union nut wrench, separate the union nut from the injector assembly first, then from the common rail assembly.

    2. Remove the No. 1 injection pipe sub-assembly.

  4. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tip:

    Perform the same procedure as for the No. 1 injection pipe sub-assembly.

  5. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tip:

    Perform the same procedure as for the No. 1 injection pipe sub-assembly.

  6. REMOVE NO. 1 GLOW PLUG CONNECTOR

    1. A199735

      Remove the 5 screw grommets.

    2. A199736

      Remove the nut and disconnect the glow terminal.

    3. Remove the 4 nuts and No. 1 glow plug connector.

  7. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    1. A199737

      Remove the No. 2 intake manifold insulator.

  8. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY

    1. A199738

      Disconnect the 4 connectors from the 4 injector assemblies.

    2. A199739C04

      *a

      Lock Bush

      Pull up the lock bush as shown in the illustration and separate the nozzle leakage pipe assembly.

      Note:

      Do not separate the nozzle leakage pipe assembly by pulling on the hose portion. Separate it while holding onto the lock bush portion.

  9. REMOVE NO. 1 NOZZLE HOLDER CLAMP

    1. A199740C01

      *1

      Nozzle Holder Clamp

      *2

      Nozzle Holder Clamp Seat

      *3

      Washer

      Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  10. REMOVE NOZZLE HOLDER CLAMP SEAT

    1. A199741

      Remove the 4 nozzle holder clamp seats form the cylinder head.

  11. REMOVE INJECTOR ASSEMBLY

    1. A199742

      Remove the 4 injector assemblies from the cylinder head.

      Note:

      • Each injector assembly has its own fuel injection part number. When replacing the injector assemblies, store them in the correct order so that they can be returned to their original locations when reassembled.

      • Arrange the injector assemblies, clamps, washers, bolts and clamp seats in the correct order.

  12. REMOVE INJECTION NOZZLE SEAT

    1. A199743

      Remove the 4 injection nozzle seats from the injector assemblies or cylinder head.

      Note:

      When removing the injector assembly, check that the injector nozzle seat is either attached to the injector assembly, or remains in the cylinder head.