Removal

Fuel Injector

Removal
1. Remove the engine harness connectors (throttle position sensor, EGR valve, fuel pressure sensor, and all of fuel injectors).
2. Remove the EGR cooler; 2nd.
a. Remove the eight bolts (2) from the both sides of the EGR cooler; 2nd.
b. Remove the EGR cooler duct securing bolts (3) in order to make the gap between EGR cooler and duct.
c. Remove the gaskets (1) from the both sides of the EGR cooler; 2nd.
d. Remove the EGR cooler; 2nd.

NOTE: Do not disconnect the water hoses (4) from the EGR cooler; 2nd.







3. Disconnect the glow plug control module (GPCM) harness connector.
4. Remove the GPCM with the bracket.
5. Remove the cylinder head cover.







6. Alternately loosen the fuel injector terminal nuts a little at a time in sequence. Several loosening cycles should be required before the nuts are loose.
7. Loosen the fuel injector harness bracket bolts. Remove the inside connector and the harness bracket.
8. Remove the fuel injector leak-off pipe.
9. Remove the lower cover.







10. Remove the fuel injection pipe clips and the injection pipes.







11. Loosen the fuel injector clamp fixing bolts and remove the fuel injectors.

If the fuel injectors are difficult to remove, use the fuel injector remover. Install the fuel injector remover to the leak-off pipe attachment part on the fuel injector. Use a sliding hammer to force the fuel injector clamp off the fuel injector.

NOTE: Do not remove the fuel injector sleeve. If injector sleeve is removed with injector, the injector sleeve MUST be replaced.

Special tools
Fuel injector remover: EN-46720
Sliding hammer: J-23907







12. Mark each fuel injector with the number of the cylinder from which it was removed. Store the fuel injectors in a safe place. Position the fuel injector so that the nozzle is protected.

NOTE: Do not tamper with the electromagnetic portion of the fuel injector. Reduced electromagnetic function will result in injector failure.







Recording Fuel Injector Flow Rate Information from the ID plate on the replaced injector housing; Record 24 figures of each fuel injector ID plate.

The correct order for the fuel injector flow rate for the following illustration is as follows: 67 2B 50 00 0F 15 13 00 15 18 00 18