FUEL INJECTOR > REMOVAL

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NOTICE:
  1. 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.
  2. 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.


1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
w/ Navigation System (for HDD):
After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.


2. REMOVE NO. 1 ENGINE COVER


    A203808

  1. Detach the 4 clips and remove the engine cover.

    NOTICE:
    Attempting to detach both the front and rear clips at the same time may cause the cover to break.


3. DISCONNECT ENGINE WIRE


A207973

  1. Disconnect the vacuum regulating valve connector.

  1. Disconnect the vacuum switching valve connector.

  1. Disconnect the 4 injector connectors.

  1. Remove the grommet and nut, and disconnect the glow plug wire harness.

  1. Disconnect the fuel pressure sensor connector.

  1. Disconnect the emission control valve wire connector.

  1. Disconnect the pressure discharge valve connector.

  1. Remove the bolt and disconnect the engine wire from the bracket.

  1. Remove the bolt and 5 nuts, and disconnect the engine wire.



4. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    A208830

  1. Detach the clamp and disconnect the mass air flow meter connector.

  1. Disconnect the PCV hose.

  1. Disconnect the air cleaner hose.

  1. Detach the 3 clips and remove the air cleaner cap.



5. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


6. REMOVE AIR CLEANER CASE


    A208831

  1. Detach the clamp.

  1. Remove the 3 bolts and air cleaner case.



7. REMOVE INJECTION PIPE SUB-ASSEMBLY

NOTICE:
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.


    A203038

  1. Remove the 2 bolts and 4 injection pipe clamps.

  1. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

  1. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

  1. Remove the 4 injection pipes.



8. REMOVE FUEL HOSE PROTECTOR


    A206325

  1. Disconnect the connector.



    A197570

  1. Remove the bolt and fuel hose protector.



9. REMOVE FUEL TUBE SUB-ASSEMBLY


    A203047

  1. Disconnect the exhaust fuel addition injector connector.



    A203048

  1. Turn the retainer as shown in the illustration.



    A203049

  1. Disconnect the fuel tube from the exhaust fuel addition injector.



    A203050E02

  1. Remove the check valve and gasket.

    Text in Illustration 
    *1
    		Check Valve

  1. Remove the union bolt, gasket and fuel tube.



10. REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    A203171

  1. Using pliers, grip the claws of the 3 clips and slide the 3 clips to disconnect the 3 fuel hoses.



    A205206E02

  1. Remove the check valve and gasket.

    Text in Illustration 
    *1
    		Check Valve

  1. Remove the bolt and No. 2 nozzle leakage pipe.



11. REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    A203040

  1. Remove the 4 union bolts and 4 gaskets.

  1. Remove the bolt and No. 1 nozzle leakage pipe.



12. REMOVE NO. 1 NOZZLE HOLDER CLAMP


    A203042

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



13. REMOVE INJECTOR ASSEMBLY

  1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

  1. Remove the O-ring from each injector.

    NOTICE:
    When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.