FUEL INJECTOR > REMOVAL

for Preparation Click here



1. REMOVE EGR WITH COOLER PIPE ASSEMBLY

  1. Remove the EGR with cooler pipe assembly (Click here).



2. REMOVE NO. 1 EGR COOLER BRACKET


    A202939

  1. Disconnect the vacuum hose.

  1. Remove the 2 bolts and No. 1 EGR cooler bracket.



3. REMOVE NO. 2 INJECTION PIPE CLAMP


    A202913

  1. Remove the nut and both sides of the No. 2 injection pipe clamp.



4. REMOVE NO. 1 INJECTION PIPE CLAMP


    A202898

  1. Remove the 2 nuts and both sides of the No. 1 injection pipe clamp.



5. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY


    A202900E01

  1. Using a union nut wrench (17 mm), separate the union nut from the injector first.

  1. Then remove the union nut from the common rail, and remove the injection pipe.
    Text in Illustration 
    *1
    		No. 1 Injection Pipe
    *2
    		No. 2 Injection Pipe
    *3
    		No. 3 Injection Pipe

  1. 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.



6. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

HINT:
Perform the same procedure as for injection pipe No. 1.



7. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

HINT:
Perform the same procedure as for injection pipe No. 1.



8. REMOVE NO. 1 GLOW PLUG CONNECTOR


    A202901

  1. Remove the 5 screw grommets.



    A202902

  1. Remove the nut and disconnect the glow terminal.

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



9. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


    A202940

  1. Remove the No. 2 intake manifold insulator.



10. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    A202904

  1. Disconnect the 4 injector connectors.



    A202905E01

  1. Pull up the lock bush as shown in the illustration and separate the nozzle leakage pipe.
    Text in Illustration 
    *1
    		Lock Bush

    NOTICE:
    Do not remove the nozzle leakage pipe by pulling the hose. Remove by holding the lock bush.



11. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    A202907E01

  1. Remove the 4 bolts, 4 washers, and 4 nozzle holder clamps.
    Text in Illustration 
    *1
    		Washer
    *2
    		Nozzle holder clamp
    *3
    		Nozzle holder clamp seat



12. REMOVE NOZZLE HOLDER CLAMP SEAT


    A202908

  1. Remove the 4 nozzle holder clamp seats from the cylinder head.



13. REMOVE INJECTOR ASSEMBLY


    A202909

  1. Remove the 4 injectors from the cylinder head.

    HINT:
    1. 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.
    2. Arrange the injectors, clamps, washers, bolts and clamp seats in the correct order.



14. REMOVE INJECTION NOZZLE SEAT


    A202910

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

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